Thesis Sample

Wire Case Protector from Recycled PET and NLR 1

Chapter 1

INTRODUCTION

1.1 Background of the Study

Electrical installations, such as electrical wires, are vital components in any facility.

Primarily made up of rubber and polymers, electrical wires are susceptible to anthropogenic and

environmental hazards such as pilferage, fire, or even dirt. With this, protection of electrical

wires is also vital for it to prolong its service life and among the many ways to protect installed

electrical wires is using wire case protector. For this reason, new and innovative material for

wire case should be studied in order to develop a product which is adaptable to hazardous

environment.

Polyethylene Terephthalate, commonly known as PET, is one of the most widely used

plastics in the world. The properties of PET make it ideal for a number of different uses and

these advantages make it one of the most common plastics available today. PET is commonly

used as packaging material for drink bottles, including water and soft drinks. PET is a

thermoplastic type of plastic that becomes moldable above its specific temperature and returns to

its solid state upon cooling. For this reason, PET can be reshaped and turned into a new and

distinctive application.

Another material that is widely used is Natural Latex Rubber. Natural latex rubber is an

elastic material obtained from Hevea Brasiliensis tree that is used in production of latex gloves,

latex condoms and latex clothing. Natural latex rubber also exhibits excellent mechanical

properties. Currently, the disposed natural latex rubbers are used as raw material in road


industry. It serves as polymer modifier that enhances the physical and chemical properties of the

material.

Combining the properties of PET and natural latex rubber, the researchers will be able to

produce a new type of wire case protector which is made from recycled PET bottles and natural

latex rubber gloves.

Currently, there are a handful of branded products for wire case protector all for the

purpose of protection of electrical wires. In the advent of new products, it is important to

continuously develop alternative products which are more adaptable to the needs of the

industries and institutions. It is also important that the base material to be used shall produce a

durable and fire resistant wire case protector. With this in mind, it can be assured that the safety

of the end users will not be compromised.

1.2 Objectives

The general objective of the study is to produce a wire case protector from recycled

polyethylene terephthalate bottles and natural latex rubber gloves for structural applications.

The specific objectives of the study will be the following:

1. To produce a wire case protector from polyethylene terephthalate (PET) and natural latex

rubber (NLR) with the following compositions:

a. 80 grams of PET, 3 grams of NLR, 5 grams of talc, and 1.5 grams of glycerin;

b. 85 grams of PET, 3 grams of NLR, 5 grams of talc, and 1.5 grams of glycerin; and

c. 90 grams of PET, 3 grams of NLR, 5 grams of talc, and 1.5 grams of glycerin


2. To test the produced wire case protectors in terms of the following mechanical properties:

a. Flammability

b. Water Absorbency

c. Crush Resistance

3. To determine the best composition for producing Polyethylene Terephthalate – Natural

Latex Rubber wire case protector.

4. To compare the best produced wire case protector with the commercially available in

terms of:

a. Flammability

b. Water Absorbency

1.3 Hypotheses of the Study

To answer the objectives of determining the best ratio in producing wire case protector

from recycled polyethylene terephthalate and natural latex rubber, the researchers had come up

with these following hypotheses:

1. There is no significant difference in the Flammability of the produced wire case

protectors with varying amounts of recycled polyethylene terephthalate.

2. There is no significant difference in the Water Absorbency of the produced wire case


3. There is no significant difference in the Crush Resistance of the produced wire case



4. There is no significant difference between the produced wire case protector and the

commercially available wire case protector in terms of Flammability.

5. There is no significant difference between the produced wire case protector and the

commercially available wire case protector in terms of Water Absorbency.

1.4 Significance of the Study

The study makes alternative way to produce a wire case protector from recycled

polyethylene terephthalate bottles and used natural latex rubber gloves that are suitable for

structural purposes. Moreover, this study will benefit the following:

Community

This study can help people to have a healthy living and clean environment. Also, since it

includes recycling, it can generate livelihood and create job to unemployed.

Environmental Sector

One of the serious problems that the society should consider is solid waste management.

The researchers had utilized recycled polyethylene terephthalate bottles and used natural latex

rubber gloves to reduce the solid waste problem.

Household

The function of the wire case is to provide safety. This is applicable for people who are

not yet well informed regarding the danger an electrical wiring could bring. Installing it to

electrical wiring at home could minimize the risk and prevent accident.

Future Researchers

The study can benefit future researchers by providing them new knowledge and ideas in

innovating the wire case protector and by giving future references for their studies.


1.5 Scope and Limitation

The study covers on creating a wire case protector from recycled polyethylene

terephthalate bottles and natural latex rubber. The polyethylene terephthalate used are soda and

water bottles only. The flammability, water absorbency, and crush resistance are of great

importance and to be taken in consideration in this study. The crush resistance comparison

between the better produced wire case protector and commercial wire case protector are not

taken in consideration, due to technical differences of crush resistance equipment used to the

standard crush resistance. For crush resistance test, the researchers used the Universal Testing

Machine 100T Cap. to determine the crush resistance of produced wire case protectors.

The dimension of the proposed wire case protector will not be exactly the same compare

to the standard dimension available in the market which is 8 ft. x 2.5 cm. x 1.3 cm. The proposed

dimensions are 15 x 2.5 x 1.3 centimeters. Instead of extruders and injection moulding, the

researchers improvised an aluminum mold to form the product. Other tests not mentioned above,

as well as the cost of production will not be included in this study.

Due to unavailability of oven for melting plastics, the researchers used an oven for

baking cakes and pastries. The raw materials to be used such as polyethylene terephthalate

bottles and natural latex rubber gloves were collected within Bacolod City area only. Natural

latex rubber gloves were collected only from diagnostic laboratories and dental clinics.

Collection of natural latex rubber gloves from hospitals were not gathered due to some reason

that it may cause disease.


1.6 Definition of Terms

The researchers gave conceptual and operational definitions to the following terms for

further understanding of the study.

Ambient Temperature. It is the coldness or warmness temperature of the surrounding.

American Society for Testing and Materials (ASTM). It is a globally recognized leader in the

development and delivery of international voluntary consensus standards. It is used around the

world to improve product quality, enhance safety, facilitate market access and trade, and build

consumer confidence (ASTM International).

ASTM D568. It is the standard testing methods for determining the flammability of plastic

material.

ASTM D570. It defines as the standard testing method for water absorption of a plastic material.

ASTM D695. It is the standard testing method for crush resistance of a plastic material.

Binder. It is any material or substance that holds other materials together.

Calcium Carbonate (CaCO3). It is an additive that is used for improving the fire resistance of a

material.

Curing. It is the hardening process of polymer for it to be stable before subjecting into other

processes. For this study, the hardening process of wire case protector for it to be stable is 24

hours.

Crush Resistance. It is the ability of wire case protector to resist the applied compressive

strength.


Flame Retardant. It is a substance/chemical added into a material to inhibit or resist the spread

of fire.

Flammability. It refers to the tendency of a material to ignite easily and burn rapidly with a

flame.

Glycerin. It is an example of plasticizer used for another kind of characteristics to a polymer

based material.

Lubricant. It is a substance applied to a mold to prevent the material from sticking.

Natural Latex Rubber. It is an elastic material obtained from the latex sap of trees that is used

in the production of surgical gloves. It forms hard and more or less flexible bond instantly upon

cooling.

Plasticizer. It is a substance added to plastics or other materials to make them more flexible.

Polyethylene Terephthalate (PET). It is a thermoplastic polymer resin of the polyester family

and is used in synthetic fibers, beverages, food and other liquid container.

Polymer Modifier. It is a chemical substance added to the backbone of a polymer to change the

chemical and physical properties of the polymer.

Self-Extinguishing. It is the ability of wire case protector to cease burning once the source of the

flame has been removed.

Talc. It is a very soft white mineral added into a material used as a flame retardant.

Thermoplastic. It is a type of plastic that becomes liquid when heated and hard when cooled.


UL94V-0. It is a flammability specification for a wire case protector. The wire case protector

may not burn with flaming combustion for more than 10 seconds after either application of test

flame and the total flaming combustion time may not exceed 50 seconds.

Underwriters Laboratories (UL). It is the largest and best known independent, not-for-profit

testing laboratory in the world. The laboratory provides a full spectrum of conformity and quality

assessment services to manufacturers and other organizations.

Water Absorbency. It is a measure of the amount of water absorbed by the material in a given

period of time.

Wire Case Protector. It serves as shield for wires from dirt and fire and provides an acceptable

passageway for wiring.


Chapter 2

REVIEW OF RELATED LITERATURE

This chapter discusses different concepts, literature and studies related to wire case

protector.

2.1 Related Concepts

2.1.1 Wire Case Protector

Wire case protector, commercially known as wire molding, is PVC-based type of non-

metal conduit designed to provide an aesthetically acceptable passageway for wiring without it

inside or behind the wall. The wire case protector has an open face with removable cover secured

to the surface, and wire is placed inside (www.electrical-cconduit.blogspot.com, 2012). Wire

case protector is used to keep the route wire and cables neat, protected and, best of all, out of

sight. Wire case protector is used in schools, houses, hospitals, and offices to guide cables from

the telecommunication closest to each work station. It can be cut to customize to any application

and the surface can be painted to match décor (www.CableOrganizer.com, July 2013).

Figure 2.1: Commercially Available Wire Molding


2.1.1.1 Production of PVC Wire Case Protector

In the production of wire case protector using PVC, PVC is not used as a pure polymer.

Since intrinsically PVC is a rigid material and wire/cable insulation must be flexible, there has to

be a significant loading of a plasticizer. Wickson (1993) indicates that typical wire/cable

formulations contain 52 – 63% PVC resin, 25 – 29% plasticizer, around 16% filler (but

occasionally as low as 5%), 2 – 4% stabilizer, 0.2 – 0.3% wax, and small amounts of lubricants

and colorants. Antioxidants are also often included in small amounts (less than 0.1%). The

plasticizer is typically either a phthalate (diisodecyl phthalate, ditridecyl phthalate) or a

trimellitate (tris(2-ethylhexyl) trimellitate), while CaCO3 and kaolin are common fillers

(Wickson, 1993).

2.1.2 Polyvinyl Chloride and Its Uses

Polyvinyl chloride (PVC) is a synthetic polymer material (or resin), which is built up by

the repetitive addition of the monomer vinyl chloride (VCM) with the formula CH2=CHCl. The

chlorine in PVC represents 57% of the weight of the pure polymer resin. 35% of chlorine from

the chloralkali electrolysis eventually ends up in PVC, which thus constitutes the largest single

use. (Brussels, 2000). Polyvinyl chloride is a major plastic material finds widespread use in

building, transport, packaging health care, electrical and electronic applications. PVC is a very

durable and long lasting construction material which can be in variety of applications, either

rigid or flexible. PVC has excellent electrical insulation properties, making it ideal for cabling

application. Its good impact strength and weatherproof attributes make it ideal for construction

products (www.pvcexplained.co.uk, July 2013). PVC is never used alone. It is always mixed

with stabilizers, lubricants, plasticizers, fillers, and other additives to make processing possible,


all of which can influence its physical and mechanical properties. The weight percentage in

producing the PVC plastic components is shown in the following table (Bedonia, et. al. 2006).

Table 2.1: Weight Percentage Comprising the PVC Plastic

Raw Material Weight %

PVC Resin 61.4

Plasticizer 30.5

Filler 6.1

Pigment 1.7

Stabilizer/Lubricant 0.3

2.1.2.1 Classification of PVC-based Wire Protector

The PVC-based wire protector for electrical installation is classified into two types, the

rigid PVC also known as unplasticized PVC (UPVC) and the flexible PVC. Rigid PVC (UPVC)

which is mechanically tough, fairly good weather resistant, water and chemical resistant,

electrically insulating, and relatively stable to heat and light (Brussels, 2000). Through addition

of stabilizers, it hinders the loss of chlorine in the form of hydrogen chloride (HCl) when

exposed to heat and ultraviolet light. Hence, stabilizers prevent degradation by heat and light.

Stabilizers are often composed of salts of metal like lead, cadmium, antimony, zinc and

organotin compounds (Brussels, 2000). UPVC is more often produced than flexible PVC.

According to PVC plus (2012), approximately 70% of PVC produced is used to manufacture

rigid products window profiles and pipes, which recognized as different by their longevity and

weather resistance.


The other type of PVC-based wire protector is the flexible PVC. With the addition of

plasticizers to raw PVC, it softens and makes the PVC pliable to certain applications (Belliveau,

2004). Plasticizers provide special properties same like to rubber material. Flexible PVC has this

naturally hard material but flexible and elastic property. It retains its shape when deflected (PVC

plus, 2012). Esters from phthalic acid also known as phthalates are the most commonly used

plasticizers for PVC. Flexible PVC is less used due to some human and environmental health

problems. Roughly, 30% covers the usage of flexible PVC (Belliveau, 2004). The table below

shows the other typical uses for rigid PVC and flexible PVC (Allsopp and Vianello, 2000).

Table 2.2: Typical Used for Rigid and Flexible PVC

Application Rigid PVC Flexible PVCConstruction window frames, gutters, pipes, waterproof membranes, cable insulation roof

housesiding, ports, roofing lining, greenhouses

Packaging bottles, blister packs, transparent cling film

packs, and punnets

Transport car seat backs underseal, roof linings, leathercloth upholstery,

wiring insulation, window seals, decorative trim

Medicaloxygen tents, bags and tubing for blood transfusions,

drips and dialysis liquids

Clothing safety equipmentwaterproofs for fishermen and emergency services,

life-jackets, shoes, wellington boots, aprons and

baby pants

Others floppy-disk covers, credit cards conveyor belts, inflatables, sport goods, toys

2.1.3 Polyethylene Terephthalate

Polyethylene Terephthalate, abbreviated as PET is one of the different types of plastics.

PET is a thermoplastic polymer resin and belongs to the family of polyesters and is highly

recyclable from bottles and other applications. It is used in many different products because of its

good properties. The recycling symbol for PET and repeating unit are shown below:


Figure 2.2: PET Recycling Symbol and Repeating Unit

2.1.3.1 Properties of Polyethylene Terephthalate

PET’s melting point is between 250°C to 260°C and the boiling point is 350°C. The

general properties of PET are typical of other semi-crystalline performance plastics: very good

temperature stability, good electrical properties, good chemical resistance, good weathering

resistance, low coefficient of friction, excellent toughness and high clarity when in amorphous

state (www.zeusinc.com, 2010).

PET has good resistance to most acids, alkalis, alcohols, greases, and oils. PET is very

suitable for food contact and many of the major applications involve food contact. Extensive

research into the use of PET for food contact has shown that PET is very suitable for contact

with both liquids (water and soda) and with solid foods, such as bakery goods

(www.zeusinc.com, 2010).

In terms of flammability of PET, the Underwriters Laboratories (UL) graded PET as

UL94V-1. UL94V-1 grade means that the fire behavior of PET when it is burned at vertical

position, the flame extinguishes within 30 seconds after removal of the burner. The Limiting

Oxygen Index (LOI) for PET is approximately 21, which means there must be over 21% oxygen

present to support free combustion. Air contains approximately 21% oxygen and therefore a

material with an LOI of greater than 21 will probably not support burning in an open air situation

(www.zeusinc.com, 2010).


Table 2.3: Typical Property Values of PET

Physical PropertiesASTM Test

Unit PETMethod

Water absorption, 24 hours D570 % 0.1

Mechanical PropertiesASTM Test

Unit PETMethod

Tensile Strength at break, 73°F D638 Psi 11,500Tensile Modulus, 73°F D638 Psi 400,000Elongation at break, 73°F D638 % 70Flexural Strength, 73°F D790 Psi 15,000Flexural Modulus, 73°F D790 Psi 400,000

Thermal PropertiesASTM Test

Unit PETMethod

Heat Deflection,264 psi D648 °F 175Melting Point ---- °F 490Coefficient of Linear Thermal

D696 in./in./-°F 0.000039ExpansionApplicable Temp. Range for

---- °F 50-250Thermal ExpansionMax. Serving Temperature for

---- °F 230Long TermFlammability UL94V ---- UL94V-1

Electrical PropertiesASTM Test

Unit PETMethod

Volume Resistivity, 73°F D257 ohm-cm 10^16Dielectric Contant @ 60 Hz,

D150 ---- 3.4(73°F, 50% RH)Dielectric Strength D149 V/mil 400

2.1.3.2 Polyethylene Terephthalate as Packaging

The function of packaging is to protect the product contained so that the contents remain

fit for purpose. Polyethylene terephthalate applications have found to be increasing in the

packaging field. The chemical and physical properties of PET have made it suitable for food and

beverage packaging applications. The three major packaging applications of PET are as

containers (bottles, jars and tubs), semi-rigid sheet for thermoforming (trays and blisters) and


thin oriented films (bags and snack food wrappers). PET is especially suitable in carbonated

drinks because of its superb gas barrier properties, particularly against oxygen and carbon

dioxide. In addition, it has very good machining characteristics and its food compatibility makes

it ideal for use in food processing equipment (International Life Sciences Institute, 2000).

2.1.3.3 Polyethylene Terephthalate in the Philippines

In the Philippines, Polyethylene Terephthalate (PET) plastic is a widely accepted and

very popular packaging material particularly for food because of its good performance, relatively

cheap cost and easy reproducibility. Because of the popularity and commonly used in packaging

for food and beverage, PET plastic is one of the enormous wastes in the country. Waste recovery

and recycling programs are being promoted because of the growing concern of disposal and

recycling of wastes (Basilia and Valencia, 2008).

2.1.4 Natural Latex Rubber

Latex is a mixture of organic compounds produced by some plants in special cells called

caticifers. The composition of latex differs from plant to plant. Most natural rubber comes from a

single species of tree, Hevea brasiliensis. Though native to South America, H. brasiliensis is

planted in large plantations in Southeast Asia, including Malaysia (Stanley Gomez Sdn. Bhd,

August 2013).

Rubber trees take around 5 years to grow from a seedling to maturity, or a point that it

can start to produce rubber. It has an economic life of about 25 to 30 years. Trees are tapped by

removing thin strips of bark, which disrupts the laticifers. The latex then flows down grooves cut

in the tree and drips into collection cup (Stanley Gomez Sdn. Bhd., August 2013).

2.1.4.1 Natural Latex Rubber Properties


After preparation, processed natural latex turns into a rubber with an exceptional

resistance to wear and tear, great tensile strength, resilience and elongation. It is resistant to

common abrasives and works well in low temperature environments; however, latex-based

rubbers should be treated with special chemicals and additives because they are easily corroded

by heat, sunlight and even oxygen. The most ideal temperature range when using latex is

between -55°C and 82°C. The melting point of latex rubber is around 250°F to 350°F (121°C to

177°C) (Johnson, n.a.). Based on the Material Safety Data Sheet of FLEXITECH SDN. BHD.

natural latex rubber glove, has the following properties:

Table 2.4: Physical Properties of Natural Latex Rubber GlovePhysical Properties Before Aged After Aged

Tensile Strength (MPa) 21 16Elongation (%) 700 500

Remark: 10% lower for textured surface gloves

2.1.4.2 Composition of Natural Latex Rubber Gloves

Latex is generally made up of around 55 to 65 percent water and 30 to 40 percent of

rubber material. It also may contain sugar, resin, protein and ash. When latex is processed into a

workable material like a surgical glove, it undergoes exposure to sulfur, carbon black and oil.

These materials are used to make the latex stronger and easier to manipulate and use (Stanley

Gomez Sdn. Bhd., August 2013). Based on the Material Safety Data Sheet of FLEXITECH

SDN. BHD. natural latex rubber glove has the following composition:

Table 2.5: Primary Material: Gloves are made from natural rubber (NR) latex


Other Ingredients Content (%)Natural Latex 96.94Zinc Oxide 0.48Sulphur 0.73Titanium Dioxide (White Pigment) 0.73Zinc Dibutyl Dithiocrbonate 0.29Sodium Napthalene Sulfonate 0.05Formaldehyde Condensate Butylated Reactive Product of P-Cresol and Dicyclopentadiene 0.73Potassium Hydroxide 0.05

Defoamer 0.01

All the above chemicals used are non-toxic or non-hazardous.

2.1.5 Additives

One way to improve the performance characteristics of plastic products is to compound

resins with additives and fillers. Additives help fight against factors such as heat, chemicals, or

light. Plastics are extremely successful commercially, it never reach acceptable performance

standards either in properties or processing without the incorporation of additives. With the

inclusion of additives, plastics can be used in a variety of areas competing directly with other

materials. Without additives, plastics would not work, but with them they can be made safer,

cleaner, tougher and more colorful (www.blackwellplastics.com, August 2013).

2.1.5.1 Glycerin

Chemically, glycerin is a trihydric alcohol which is very stable under most trihydric

alcohol conditions, but which can be reacted to form many derivatives. Physically, it is a clear,

almost colorless, viscous, high-boiling liquid miscible with water and alcohol, and like these


materials, a good solvent. One of its applications is as plasticizer on polymer products that

increases the flexibility and elasticity of the product (www.bpf.co.uk, September 2013).

2.1.5.2 Talc (Calcium Carbonate)

Calcium carbonate or Talc is the most widely used mineral due to its wide availability,

ease of processing to specific particle sizes and it’s compatibility with a wide range of polymer

types. It is used for its excellent optical properties, ability to improve impact strength, role as a

processing aid, ability to replace expensive plastic resins and used as fire retardants (Weil and

Levchik, 2009).

Talc is mined for both industrial and artistic reasons. Talc is used for mainly industrial

departments such as in plastics, rubber, electric wire, electric cable, paint, printing ink, oil paint,

papermaking, agrochemicals, foodstuff and medicine. Calcium Carbonate takes functions of

being strength increasing, tensile resistant, filling and fire retardant. In polypropylene

compounds, about 3% of Talc is filled to improve heat deformation resistance. Blends that

contains more than 3% flame retardant component increase the products compressive strength

and rigidity (Bedonia, et.al. 2006).

2.1.6 Polymer Modifier

Polymer modifiers, commonly referred to as functionalized polymers, coupling agents,

compatibilizers or impact modifiers, are polymeric materials which have a functional unit grafted

onto the backbone of the polymer. Polymer modifier allows fillers such as talc, calcium

carbonate, nanoclays & glass to be chemically bonded to the polymer or dissimilar polymers to


become compatible with each other. Additionally when functionalizing an elastomer the

functionalized products will be compatible with other rigid thermoplastics to provide improved

impact modification (www.addivant.com, October 2013).

2.1.7 Wire Case Protector Standards

The wire case protector must be Underwriters Laboratories (UL) listed and exhibit non-

flammable self-extinguishing characteristics, tested to comparable specifications of UL94V-0.

The wire case protector base, cover, and divider shall be available in 8’ and 10’ lengths (Panduit

Corp).

There are types of wire case protector that has one compartment design and some has two

or three compartments design. The commonly used wire case protector is the one with one

compartment design. It has one wiring channel and has an integral hinge that attaches the cover

to the base. The wire case protector is usually manufactured of rigid PVC compound. The base

must have a smooth texture and available in three colors, off-white, electrical ivory, and white

(Panduit Corp). The figure below shows the commercial sizes of wire case protector.

Figure 2.3: Commercial Sizes of Wire Case Protector

2.1.8 Properties of Wire Case Protector


There are various characteristics that non-metallic wire case protector must possess.

Properties such as excellent moisture and corrosion resistance, mechanical strength, flame

retardant, and low-smoke-producing must be designed into the raceway system

(www.accessengineeringlibrary.com, August 2013).

Table 2.6: Physical Properties of Wire Case ProtectorImpact Resistance 5 ft. lbs.Crush Resistance 300 lbs.Tempearature Range -25.6°F to 158°FFlame Rating UL94V-0Material UV Stabilized PVC

According to Underwriters Laboratories (UL), the flammability of a wire case protector

must be classified to UL94V-0 specifications. The specimen must extinguish within 10 seconds

after subjecting into blue flame to rate it as a UL94V-0 (www.ul.com, August 2013).

2.1.9 Flammability

Wire case protectors are tested for its flammability in order to distinguish its self-

extinguishing characteristic. Flammability, also called flame resistance, is a term that indicates

the measure of the ability of a material to support combustion. Several tests measure this

property. In this test, Burning Vertical Test or the ASTM D568 is usually used. In a test, plastic

strip is ignited and the ignition source (flame) is removed. The time and amount of material

consumed are measured and the result is express in mm/min (Lokensgard, 2010).

Self-extinguishing indicates the material will not continue to burn once the flame is

removed. Nearly all plastics may be made self-extinguishing with the proper additives

(Lokensgard, 2010). (See table 2.7 for the classification of vertical burning)


Table 2.7: Underwriters Laboratories Vertical Burning Rating

Vertical Ratings RequirementsUL94 V-0 Burning must self-extinguish within 10 seconds

Specimen must not drip flaming particles that ignite the cottonUL94V-1 Burning must self-extinguish within 30 seconds

Specimen must not drip flaming particles that ignite the cottonUL94V-2 Burning must self-extinguish within 30 seconds

Specimen can drip flaming particles that ignite the cotton

2.1.10 Water Absorbency

The tendency of plastics to absorb moisture simply cannot be ignore since even the slight

amount of water can significantly alter some key mechanical, electrical, or optical property.

ASTM D570 is the most commonly used test for water absorption of polymers and some other

plastics. The purpose of water absorption is to express a sense as to what the specific effects of a

humid environment or long-term exposure to water would be on the polymer under examination

(www.polymer-filler.blogspot.com, 2008).

According to Underwriters Laboratories (2013), the percent increase in weight of a

material after exposure to water under specified conditions. Water absorption can influence

mechanical and electrical properties. Factors such as the type of material, additives, temperature,

and length of exposure can affect the amount of water absorbed.

2.1.11 Crush Resistance

Crush resistance testing is the measurement of a compressive load to a point when a

sample deforms, fractures, shatters or collapses. Compressive strength is the capacity of a


material or structure to withstand axially directed pushing forces. When the limit of compressive

strength is reached, brittle materials are crushed (www.matweb.com, December 2013).

Usually, a crush resistance test involves a load limit. The material to be tested is compressed and

compared to the load limit. Maximum load, load at break and work at maximum load are

calculated. By crushing samples of the material, significant facts can be learned for predicting

the performance of full capacity machines with acceptable accuracy. In this test ASTM D695 is

the standard method to be used (www.matweb.com, December 2013).

2.2 Related Studies

2.2.1 Flexible Wiring Shield from Recycled Polypropylene and Ethylene Vinyl Acetate

Copolymer

A study of creating of flexible wiring shield from recycled Polypropylene and Ethylene

Vinyl Acetate Copolymer (EVAC) with the addition of the additives such as talc that act as a

flame retardant and glycerin that make the wiring shield flexible, was found out that it is possible

to blend a thermoplastic material (Polypropylene) with a hot melt adhesive material (EVAC) and

could be an alternative to PVC-based flexible wiring shield. The sources of polypropylene were

bottle caps of shampoo, polypropylene from tire toys and noodle cups.

The blend ratios of the raw materials were identified by taking the one raw material into

constant amount as well as the additives, while the other raw material varies the amount and this

was done conversely. The blends were created to establish a probable basis and identification of

the effect of varying the two raw materials in the blend for determination of the optimum blend.

The polypropylene was melted at 150-170°C and EVA copolymer was melted at 80-84°C in

oven. After the two raw materials reached their respective melting point, the raw materials were


then blended gradually, and then the additives were added to the homogeneous mixture. The

blend was then poured into the mold and cooled to room temperature. The flexible wiring shield

has the dimensions of 30 x 2.5 x 1.3 centimeters. The curing time for the blend was 24 hours.

In order to determine the optimum blend of flexible wiring shield, the produced products

were examined through Glow Wire Test (IES 695-2-1) and Bend Test (ASTM D-790). The

Glow Wire Test determines the thermal stress of the product, while the Bend Test determines the

material’s elongation after it was subjected to a constant position over a period of time. After the

product characterization, the optimum blend was identified. The optimum blend of flexible wire

shield was 1 part of polypropylene (cup noodles) and 3 parts of EVA copolymer. According to

the study, the 1:3 polypropylene-EVA copolymer proportion obtained a product that is flexible

compared to PVC and passed the requirement for thermal stress.

The table in the next page is the optimum blend of polypropylene and EVA copolymer

based on the result of the testing.

Table 2.8: Weight Composition for Optimum Blend of Polypropylene and EVA Copolymer

Type of Recycled

Polypropylene

Weight

Polypropylene

Weight EVA

Copolymer

Weight

Talc

Weight

Glycerin

Noodle Cups 40g 120g 5g 1.5g

%Weight 24% 72% 3% 0.9%

The researchers of the study strongly recommended to use other binder such as butyl

rubber to enhance the mechanical properties of the product (Bedonia, et.al. 2006).

2.2.2 Use Of Natural Rubber Latex In Reseal Binders


Natural rubber latex may be added to asphaltic binder for resealing works. It has the

effect of raising the softening point, and increasing the viscosity and elasticity or elastic recovery

of the binder. As from the experience in Dunedin district, it has been found that the use of natural

rubber latex produces an increase in initial toughness, to help to prevent early chip loss or chip

roll-over and in the longer term to resist the development of reflective cracking. Its use is

generally aimed to extend the waterproof character of a reseal over an existing seal coat with

widespread cracking. In terms of blending, it has been found from experience that the best

dispersal of rubber is obtained when the asphalt cement has been heated to a temperature of

165°C (TNZ P/5P NOTES, 1985).

Natural rubber was studied as a polymer modifier for asphalt extensively in the 1950-70’s

in the UK and abroad. Also, it offers unique opportunity to road industry as a performance

enhancing, renewable, sustainable and ecologically beneficial resource available to the road

sector. Carbon Trading and other environmental factors will ensure natural rubber latex will have

a future as polymer modifier in roads (Ruggles, 2005).

2.3 Synthesis

The researchers have understood the different studies, literature and concepts in order to

support the study of creating wire case protector from recycled polyethylene terephthalate and

natural latex rubber. The researchers have come up with the following:


Polyethylene Terephthalate (PET) has an extensive range of properties. PET materials

have very good temperature stability, good electrical properties, good chemical resistance and

weathering resistance, durable, low cost and easy reproducibility. Natural latex rubber exhibits

excellent mechanical properties, such as in its tensile strength, elongation, tear resistance and

resilience. Also, natural latex rubber will serve as polymer modifier that will enhance the

chemical and physical properties of the product. The addition of glycerin and talc will enhance

the physical and chemical properties of the product. Glycerin will make the product more

flexible and addition of talc will improve the fire resistance of the produced product. The

produced wire case protectors will be then tested in terms of its flammability, water absorbency

and impact resistance.

The combination of the exceptional properties of polyethylene terephthalate, natural latex

rubber and the additives, glycerin and talc, will improve and create a new alternative for the

PVC-based wire case protector.

Chapter 3

METHODOLOGY

This chapter discusses the procedures and processes in making wire case protector. The

wire case protector, with constant dimensions of 15 x 2.5 x 1.3 centimeters, will be produced


with different proportions of polyethylene terephthalate bottles and natural latex rubber gloves,

and wire case protector with polyethylene terephthalate bottles. The wire case protector will

undergo testing and the best wire case protector will be determined.

Figure 3.1: Production of PET – Natural Latex Rubber Wire Case Protector

3.1 Production of PET – Natural Latex Rubber Wire Case Protectors

The PET bottles and natural latex rubber gloves were cut into small pieces and weighed,

were undergone the process of melting in an oven, were blended with the additives, glycerin and

talc, molded in an aluminum mold and were cured. Three compositions of wire case protectors

Preparation of PET Bottles

Preparation of NLR Gloves

Heating

250 - 260°C

Blending

180°CGlycerin

Talc

Molding

Curing

Final Product


were produced. The cut PET bottles have a varying amount while the natural latex rubber gloves,

glycerin and talc were kept at constant amount.

Table 3.1: Compositions of Wire Case Protectors

SamplePET NLR Glycerin Talc

Mass, g Mass, g Mass, g Mass, g

WCP 1 80 3 1.5 5

WCP 2 85 3 1.5 5

WCP 3 90 3 1.5 5

3.1.1 Preparation of PET Bottles and Natural Latex Rubber Gloves

The researchers collected disposed PET bottles and latex rubber gloves from Bacolod

City (schools, households, markets, dental clinics, diagnostic laboratories, etc.). PET bottles and

natural latex rubber gloves were washed with detergent soap and water to remove dirt. The

natural latex rubber gloves were then sterilized for disinfection. These were dried at ambient

temperature and then cut into small pieces. The cut raw materials were weighed at respective

amounts. (See Table 3.1 for respective composition of wire case protectors)

3.1.2 Heating and Blending

The researchers used an oven to control the temperature and to ensure the process is not

hazardous. The oven was preheated for about 10 minutes and 45 seconds to reach the 250-260°C

heat. Before putting the PET to the pan, application of cooking oil to the surface of the pan was


required to avoid PET and other raw materials from sticking to the pan. The PET sample was

then placed in the oven first due to its higher melting temperature of 260°C than natural latex

rubber which has 177°C. When PET sample was at its liquid state, the melted PET was then

removed from the oven. The melted PET was cooled down to 180°C while stirring it vigorously.

Temperature was then maintained until 180°C. The additives, talc and glycerin were then added

to the melted PET and the natural latex rubber was then added lastly. The mixture was stirred

until it reached the homogeneous mixture.

3.1.3 Molding and Curing

Before pouring the homogeneous mixture to the aluminum mold, the aluminum mold was

heated for five minutes. Then, “1 Oil” was applied to the inner part of the mold to prevent the hot

melt to stick into the mold. The hot melt was gradually poured and was cooled into the mold at

ambient temperature for one hour. After one hour, the produced wire case protector was

extracted from the mold and was set aside for twenty-four hours to prepare for testing.

3.2 Dimensions of the Wire Case Protector

The dimensions of the proposed Wire Case Protector are shown in Figures 3.2 and 3.3.


1.3cm

Gg 0.5 cm

2.5 cm

Figure 3.2: The front view of the wire case protector

15 cm

Figure 3.3: The three-dimensional representation of wire case protector

3.3 Testing

The wire case protector was subjected to flammability, water absorbency and impact

resistance test.

3.3.1 Flammability Test (ASTM D568)


Figure 3.4: Vertical Burning Test

Using the Vertical Burn Test, the sample was suspended vertically so that it can be

ignited at the bottom. After ignition, the ignition source (flame) is withdrawn and the length of

time of its self-extinguish was noted. The obtained time was then referred to Underwriters

Laboratories Vertical Burning Rating to classify its flame rate (See Table 2.7 for the

classification of vertical burning).

3.3.2 Water Absorbency Test (ASTM D570)

Using ASTM D570, the samples were weighed initially using the analytical balance,

and were submerged in distilled water at a temperature of 23°C for twenty-four hours. Samples

were then removed, patted dry with a lint free cloth, and were weighed. The percent increase in

weight during immersion was calculated as follows:

% Water Absorption = W f −W i

W i × 100

Where:


Wf = weight of the wire case protector after 24-hour water soaking

Wi = initial weight of the wire case protector

3.3.3 Crush Resistance Test (ASTM D695)

Figure 3.5: Crush Resistance Test

The researchers formed 2” x 2” x 2” cube samples of each different composition and

conducted the crush resistance testing in HVC Materials Testing Laboratory wherein Universal

Testing Machine 100T Cap. was used. In the specification of a wire case protector, around 300

lbs. is the desirable value for crush resistance.

3.4 Significant Difference Between the Wire Case Protectors

In order to determine whether there is a significant difference between the produced wire

case protectors properties, the researchers used One-way ANOVA (Analysis of Variance).

ANOVA enables the data to analyze the difference between two or more sample means. The

researchers used a One-way ANOVA Calculator in order to determine the significance difference


in the flammability, water absorbency, and crush resistance properties of the wire case

protectors. P value is calculated and compared to the critical value (0.05).

3.4.1 Scheffé Test

Scheffé Test is a pairwise comparison of every combination of group pairs. This test

calculates the mean difference for each treatment or group pair, calculates S test statistic for each

pair, and displays the P value for the comparison. The obtained P value is then compared to the

critical value (10.28). (See formulas for the combination of group pairs are below)

F12 = ( X 1−X 2 )2 N 1 N 2

SE(N 1+N 2)

F13 = ( X 1−X 3 )2 N 1 N 3

SE(N 1+N 3)

F23 = ( X 2−X 3 )2 N 2 N 3

SE(N 2+N 3)

3.5 Determining the Best Composition

The three samples of different proportions were tested for flammability, water

absorbency, and impact resistance. Criteria-Based Method was used to determine the best wire

case protector. Average value of each property was calculated. For crush resistance, the highest

value was recorded and served as the basis of the obtaining percentages of every proportion. The

lowest value was used in flammability and water absorbency for obtaining the percentages of

every proportion.


Average = Trial1+Trial2+Trial3

3

Highest average value is the highest value in every row. % is percent contribution of

each property to the overall composition of the product based on its performance. For

Flammability (F) and Water Absorbency (W), the basis is the lowest average value while for

Crush Resistance (C), the basis is the highest average value. The obtained percentages are totaled

and the highest totaled value will be the best produced product of the study.

%(F) = Lowest Average Value

AverageValuex33.33 %

%(W) = Lowest Average Value

AverageValuex33.33 %

%(C) = AverageValue

Highest AverageValuex 33.33 %

3.6 Comparing the Best Composition of Wire Case Protector to Commercial Wire Case

Protector

After determining the best composition of wire case protector, the best produced wire

case protector was then compared to the commercially available wire case protector, the Tokina

UPVC. The Tokina UPVC had undergone flammability and water absorbency test. Crush

resistance test for commercial wire case protector was not performed due to its given

specification, which is 300 lb. force. The data obtained were then compared. The researchers


used a statistical test, the T-test, in order to determine the best product of each mechanical

property.

Chapter 4

RESULTS AND DISCUSSIONS


This chapter discusses the results in relation to the different characterization of the wire

case protectors. The results were recorded, analyzed and computed by the researchers in order to

answer the objectives of the study.

4.1 Characterization

4.1.1 Flammability

FFlammab

Figure 4.1: Flammability Test Results

All of the different compositions of wire case protectors exhibit an exceptional self-

extinguishing ability. All of the wire case protectors self-extinguished not exceeding three

seconds. Based on the results, Wire Case Protector 2 exhibits the fastest time to burn off the fire.

The average time of self-extinguishing for Wire Case Protector 2 was 1.08 seconds (See Table

4.1 for the Average Test Results of the Three Wire Case Protectors). In Underwriters

Trial 1 Trial 2 Trial 30

0.5

1

1.5

2

2.5

2

1

1.51.1

0.940000000000001

1.2

1.1

1.48

2.06

Tim

e, s

ec

Wire Case Protector 1




Laboratories, a wire case protector that self-extinguishes within 10 seconds is graded as UL94V-

0. UL94V-0 is one of the most important specifications of a wire case protector. Though PET is

graded as UL94V-1 which usually self-extinguishes within 30 seconds, with the addition of talc

which is the flame retardant agent for this study well-improved the flammability of a wire case

protector.

Wire Case Protectors 1, 2 and 3 were qualified in the standards and classified as UL94V-

0 but the Wire Case Protector 2 is better than Wire Case Protectors 1 and 3 because it self-

extinguished at a very short period of time.


Wire

Case Pro

tector 1

Wire

Case Pro

tector 2

Wire

Case Pro

tector 3

0

0.05

0.1

0.15

0.2

0.25

0.3

%

Trial 1Trial 2Trial 3

Figure 4.2: Water Absorbency Results

Wire Case Protector 2 showed the least water absorption, while Wire Case Protectors 1

and 3 were slightly affected by water. The three compositions were not affected that much due to

the ability of PET resistance to water. PET has an ability to absorb water for 0.10% only. Based

on the results, Wire Case Protector 2 was considered to be the better composition among the


other samples. The least percentage of water absorption, the more desirable the wire case

protector is.





0 500 1000 1500 2000 2500 3000 3500 4000

2208.8

2054.8

2362.8

2098.8

3645.4

3159.2

3401.2

2230.8

2362.8

Trial 1 Trial 2 Trial 3

lb. force

Figure 4.3: Crush Resistance Results

Based on the results, all of the different compositions of wire case protectors exhibit an

exceptional amount of resistance to force applied. Wire Case Protectors 1, 2 and 3 carried a high

strength in crush resistance. But among the three wire case protectors, Wire Case Protector 2

resisted the highest magnitude with an average of 2643.67 lb. force. Therefore, wire case

protector 2 is the better wire case protector in terms of its crush resistance property.

The wire case protectors showed an extreme amount of load due to the presence of the

polymer modifier, the natural latex rubber. In this case, natural latex rubber bonded the other

components chemically and resulted of attaining an extreme amount of force. Based on the

standards of commercial wire case protector, a wire case protector can resist crushing for about

300 lb. force (See Table 4.1 for the Average Test Results of the Three Wire Case Protectors).


4.2 Summary of Characterization

Table 4.1: Average Test Results of Three Wire Case Protectors

Wire Case Protector

Flammability Water Absorbency Crush Resistance(sec) (%) (lbf)

1 (80 grams of PET)

1.50 0.13 2628.27

2 (85 grams of PET)

1.08 0.07 2643.67

3 (90 grams of PET)

1.55 0.21 2569.60

The table shows the summary of test results conducted on the three wire case protector

samples of various raw material concentrations. Based on the overall test results, the better

product was found to be at Wire Case Protector 2. Wire Case Protector 2 established the most

favourable result in terms of flammability, water absorbency and crush resistance.

The flammability and water absorbency tended to be inversely proportional to the

concentration of the PET at the Wire Case Protectors 1 and 2, and lost its trend at the Wire Case

Protector 3. While in the crush resistance property, the values were directly proportional at the

Wire Case Protectors 1 and 2, and lost its trend as well as at the wire case protector 3.


4.3 Determination of Significant Differences Using One-way ANOVA and Scheffé Test

4.3.1 Flammability

The obtained P value in the flammability is 0.367047 which is greater than the

significance level of 0.05. Therefore, Wire Case Protectors 1, 2 and 3 have no significant

difference in terms of their flammabilities, which means that the varying amount of

recycled PET is not related to the produced wire case protector’s flammability.


The obtained P value in the water absorbency is 0.040028 which is less than the

significance level of 0.05. This means that there is a significant difference in the water

absorbencies between at least two of the three Wire Case Protectors.

In order to further determine which pair of Wire Case Protectors, differ

significantly, the researchers conducted a Scheffé Test. Based on the Scheffé Test results,

Wire Case Protector 2 and 3 are significantly different in terms of their water

absorbencies. This means that the varying amount of PET does matter in the produced

wire case protector’s water absorbency, which means that both Wire Case Protectors 2

and 3 have better water absorbency.


The obtained P value in the crush resistance is 0.990066 which shows that the

significance level of 0.05 is greater than the obtained P value. Therefore, there is no

significant difference in the crush resistances of Wire Case Protectors 1, 2 and 3, which


means that the varying amount of recycled PET is not related to the produced wire case

protectors’ crush resistance.

4.4 Determination of Best Wire Case Protector Composition Using Criteria Based Method

Table 4.2: Results of the Accumulated Percentages of the Wire Case Protectors

WCP 1 WCP 2 WCP 3Computed

75.09 99.99 66.73Percentage

Table 4.2 shows that Wire Case Protector 2 has the highest computed average based on

the characterizations using criteria based method. Therefore, Wire Case Protector 2 is the best

wire case protector among the samples.

4.5 Comparison of Commercial Wire Case Protector from Wire Case Protector 2 using T-

test

4.5.1 Flammability

The computed t value in the flammability is |-12.734|, which is greater than the

significance level of 2.776. T-test results showed that there is an extremely significant difference

between the self-extinguishing characteristics of Wire Case Protector 2 and the commercial

sample. Wire case protector 2 showed better resistance to flame as it had additive such as talc for

fire retardant and PET which had a Limiting Oxygen Index of 21 that will not support burning in

an open air.



The computed t value in the flammability is 2.536, which is less than the significance

level of 2.776. The T- test results showed that there is no significant difference between the

water absorbency of Wire Case Protector 2 and commercial sample which means that the amount

of water absorption of both samples are similar.

4.6 Summary of T-test Results

Analysis of results using T-test shows that the researcher’s product was able to attain

desired properties and considered it comparable. Based on the results, the researcher’s product is

suitable for the alternative way to produce a wire case protector.


Chapter 5

CONCLUSIONS AND RECOMMENDATIONS

5.1 Conclusions

The study focused on creating a wire case protector from recycled polyethylene and

natural latex rubber gloves. Based on the different characterization of the product and the data

that gathered, the researchers concluded the following:

1. Wire case protector 2 (85 grams PET, 3 grams NLR, 5 grams talc, 1.5 grams glycerin)

had the best composition.

2. Wire case protector 2 attained the best value in terms of flammability, crush resistance

and water absorbency among the other compositions.

3. Using ANOVA, the researchers found out that there was no significant difference

between Wire Case Protector 1 (80 grams PET, 3 grams NLR, 5 grams talc, 1.5 grams

glycerin), Wire Case Protector 2 (85 grams PET, 3 grams NLR, 5 grams talc, 1.5 grams

glycerin) and Wire Case Protector 3 (90 grams PET, 3 grams NLR, 5 grams talc, 1.5

grams glycerin) in all properties except water absorbency. Using the Scheffé Test, to

further determine the significant difference for water absorbency, the researchers found

out that there was significant difference between Wire Case Protector 2 and Wire Case

Protector 3, which means that both Wire Case Protectors 2 and 3 have better water

absorbency.

4. The experimented product was compared to the commercially available wire case

protector. The researchers determined that the produced Wire Case Protector 2 has better

flammability and crush resistance compared to commercially available wire case

protector.


5. The researcher’s product is suitable for the alternative way to produce a wire case

protector.

5.2 Recommendations

The researchers recommend the following:

1. The use of other plasticizers that will be compatible to the raw materials.

2. The consideration of cutting the raw materials into smallest size or particle size.

3. The evaluation of the wire case protector should not be limited only to water absorbency,

flammability and crush resistance. Additional evaluation such as thermal conductivity

and impact resistance should be done to ensure product’s quality.

4. The use of extrusion and injection moulding in forming the wire case protector for

thinner dimension.

5. The enhancement of physical appearance to increase its aesthetic value.

6. The use of adhesive for the installation of wire case protector.

Thesis Sample

Documents

grams of pet

grams of nlr

properties of pet

natural latex rubber

natural latex rubber

grams of talc

resistant wire case

grams of glycerinb