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Contents Preface .................................................................................V 1 Introduction to Industrial Polymers .................................................. 1 1.1 Beginning of Industrial Polymers ................................................. 2 1.2 Polymer Families ................................................................ 4 1.3 Thermoplastic Polymers ......................................................... 5 1.3.1 Classification of Polymers by Performance ................................... 5 1.3.2 Molecular Structure of Industrial Polymers .................................. 7 1.4 Manufacturing of Industrial Polymers ............................................. 8 1.5 Compounding the Industrial Polymers ........................................... 12 1.6 Additives ...................................................................... 13 1.7 Fillers and Reinforcements ...................................................... 14 1.8 Impact Modifiers............................................................... 15 1.9 Colorants ...................................................................... 15 2 Polymeric Materials ................................................................ 17 2.1 Acrylonitrile-Butadiene-Styrene Copolymer (ABS) ................................. 17 2.1.1 Advantages ofABS ....................................................... 18 2.1.2 Disadvantages and Limitations ofABS ...................................... 19 2.1.3 Typical Applications of ABS ...............................................19 2.2 Acetal (POM, Polyacetal) ........................................................ 20 2.2.1 Advantages ofAcetal ...................................................... 23 2.2.2 Disadvantages and Limitations ofAcetal .................................... 23 2.2.3 Typical Applications of Acetal.............................................. 23 2.3 Polymethyl Metacrylate (Acrylic, PMMA) ......................................... 25 2.3.1 Advantages ofAcrylic ..................................................... 26 2.3.2 Disadvantages and Limitations ofAcrylic ...................................26 2.3.3 Typical Applications of Acrylic ............................................. 27 2.4 High Temperature Nylon (HTN) ................................................. 27 2.4.1 Advantages of HTN ...................................................... 28 2.4.2 Disadvantages and Limitations of HTN ..................................... 29 2.4.3 Typical Applications of HTN ..............................................29 2.5 Ionomer Polymers .............................................................. 30 2.5.1 Advantages of Ionomers .................................................. 31 2.5.2 Disadvantages and Limitations of Ionomers ................................. 31 2.5.3 Typical Applications of Ionomers .......................................... 32 2.6 Liquid Crystal Polymer (LCP) ................................................... 32 2.6.1 Advantages of LCP ....................................................... 33 2.6.2 Disadvantages and Limitations of LCP ...................................... 33 2.6.3 Typical Applications of LCP ............................................... 34 2.7 Polyamide (PA, Nylon) .......................................................... 34 2.7.1 Advantages of Nylon ...................................................... 37 2.7.2 Disadvantages and Limitations of Nylon .................................... 37 2.7.3 Typical Applications of Nylon ............................................. 38 2.8 Polyetherimide (PEI) ........................................................... 39 2.8.1 Advantages of PEI ........................................................ 40 2.8.2 Disadvantages and Limitations of PEI ...................................... 40 2.8.3 Typical Applications of PEI ................................................ 41 2.9 Polyarylate (PAR) .............................................................. 41 2.9.1 Advantages of PAR .......................................................43 2.9.2 Disadvantages and Limitations of PAR ...................................... 43 2.9.3 Typical Applications of PAR ............................................... 44 2.10Polyetherether Ketone (PEEK) ................................................... 44 2.10.1 Advantages of PEEK ...................................................... 45 2.10.2 Disadvantages and Limitations of PEEK .................................... 46 2.10.3 Typical Applications of PEEK .............................................. 46 2.11Polycarbonate (PC) ............................................................. 46 2.11.1 Advantages of PC ........................................................48 2.11.2 Disadvantages and Limitations of PC ....................................... 48 2.11.3 Typical Applications of PC ................................................ 49 2.12Modi?ed Polyphenylene Oxide (PPO) ............................................ 50 2.12.1 Advantages of PPO ....................................................... 51 2.12.2 Disadvantages and Limitations of PPO ..................................... 52 2.12.3 Typical Applications of PPO ............................................... 52 2.13Polybutylene Terephthalate (PBT)................................................ 53 2.13.1 Advantages of PBT ....................................................... 54 2.13.2 Disadvantages and Limitations of PBT ...................................... 54 2.13.3 Typical Applications of PBT ............................................... 54 2.14Polyethylene Terephthalate (PET) ................................................ 55 2.14.1 Advantages of PET ....................................................... 57 2.14.2 Disadvantages and Limitations of PET ...................................... 57 2.14.3 Typical Applications of PET ............................................... 57 2.15Polyethylene (PE) ..............................................................58 2.15.1 Advantages of PE......................................................... 60 2.15.2 Disadvantages and Limitations of PE....................................... 60 2.15.3 Typical Applications of PE................................................. 60 2.16 Ethylene Vinyl Acetate (EVA) .................................................... 61 2.17Ethylene N-Butyl Acrylate (ENBA) ............................................... 61 2.18Ethylene Methyl Acrylate (EMA) ................................................. 62 2.19Ethylene Ethyl Acrylate (EEA) ...................................................62 2.20Ultrahigh Molecular Weight Polyethylene (UHMWPE) ............................. 62 2.21Metallocene Polyethylene (MPE) ................................................. 62 2.22Polytetra? uoroethylene (PTFE) .................................................. 63 2.22.1 Advantages of PTFE ...................................................... 66 2.22.2 Disadvantages and Limitations of PTFE ....................................66 2.22.3 Typical Applications of PTFE .............................................. 67 2.23Polyphenylene Sul? de (PPS) ..................................................... 68 2.23.1 Advantages of PPS ........................................................ 69 2.23.2 Disadvantages and Limitations of PPS ...................................... 69 2.23.3 Typical Applications of PPS ...............................................70 2.24Polypropylene (PP) ............................................................. 70 2.24.1 Advantages of PP ......................................................... 72 2.24.2 Disadvantages and Limitations of PP ....................................... 72 2.24.3 Typical Applications of PP................................................. 73 2.25Polystyrene (PS) ................................................................ 73 2.25.1 Advantages of PS ......................................................... 75 2.25.2 Disadvantages and Limitations of PS ....................................... 75 2.25.3 Typical Applications of PS ................................................. 75 2.26Polysulfone (PSU) .............................................................. 76 2.26.1 Advantages of PSU ....................................................... 77 2.26.2 Disadvantages and Limitations of PSU ...................................... 77 2.26.3 Typical Applications of PSU ............................................... 78 2.27Polyvinyl Chloride (PVC) ....................................................... 78 2.27.1 Advantages of PVC ....................................................... 79 2.27.2 Disadvantages and Limitations of PVC ..................................... 79 2.27.3 Typical Applications of PVC ............................................... 80 2.28 Styrene Acrylonitrile (SAN) ..................................................... 81 2.28.1 Advantages of SAN ....................................................... 82 2.28.2 Disadvantages and Limitations of SAN ..................................... 82 2.28.3 Typical Applications of SAN ............................................... 82 2.28.4 Typical Applications for OSA and ASA ...................................... 83 3 Thermoplastic Elastomers (TPE) .................................................... 85 3.1 Advantages of TPE ............................................................. 85 3.2 Disadvantages of TPE ........................................................... 86 3.3 Thermoplastic Elastomer Families ................................................ 87 3.4 Thermoplastic Polyurethane Elastomer (TPU) ..................................... 88 3.4.1 Advantages of TPU ....................................................... 90 3.4.2 Disadvantages and Limitations of TPU .....................................90 3.4.3 Typical Applications of TPU ............................................... 91 3.5 Styrenic Block Copolymer (SBS) ................................................. 91 3.5.1 Advantages of SBS ........................................................ 93 3.5.2 Disadvantages and Limitation of SBS ....................................... 93 3.5.3 Typical Applications of SBS ................................................ 93 3.6 Polyole?n Thermoplastic Elastomer (TPO) ........................................ 94 3.6.1 Advantages of TPO ....................................................... 96 3.6.2 Disadvantages and Limitations of TPO .....................................97 3.6.3 Typical Applications of TPO ............................................... 97 3.7 Thermoplastic Vulcanizate (TPV) ................................................ 98 3.7.1 Advantages of TPV ...................................................... 100 3.7.2 Disadvantages and Limitations of TPV .................................... 100 3.7.3 Typical Applications of TPV .............................................. 100 3.8 Melt Processible Rubber (MPR) ................................................. 101 3.8.1 Advantages of MPR ..................................................... 103 3.8.2 Disadvantages and Limitations of MPR .................................... 103 3.8.3 Typical Applications of MPR ............................................. 103 3.9 Block Copolyester Thermoplastic Elastomer ...................................... 104 3.9.1 Advantages ............................................................. 107 3.9.2 Disadvantages and Limitations............................................ 108 3.9.3 Typical Applications ..................................................... 108 3.10Polyamide Thermoplastic Elastomer ............................................. 109 3.10.1 Advantages ............................................................. 111 3.10.2 Disadvantages and Limitations............................................ 111 3.10.3 Typical Applications ..................................................... 112 4 Liquid Injection Molding Silicone (LIM?) ........................................... 113 4.1 LIM? Silicone Processing ....................................................... 114 4.1.1 Liquid Components Feeding System....................................... 114 4.1.2 Injection Molding Machine Modi? cations ................................. 115 4.1.3 LIM? Mold Requirements ................................................ 115 4.1.4 LIM? Mold Design Recommendations .................................... 116 4.2 Advantages of LIM ............................................................ 116 4.3 Disadvantages and Limitations of LIM ........................................... 117 4.4 Typical Applications of LIM ....................................................117 5 Industrial Thermoset Polymers ..................................................... 119 5.1 Polyester Alkyd (PAK) ......................................................... 121 5.1.1 Advantages of PAK ......................................................122 5.1.2 Disadvantages and Limitations of PAK..................................... 122 5.1.3 Typical Applications of PAK .............................................. 122 5.2 Diallyl Phthalate/Isophthalate (DAP, DAIP) ...................................... 123 5.2.1 Advantages of DAP ...................................................... 124 5.2.2 Disadvantages and Limitations of DAP ....................................124 5.2.3 Typical Applications of DAP .............................................. 125 5.3 Melamine Formaldehyde (MF) .................................................. 125 5.3.1 Advantages of MF ....................................................... 126 5.3.2 Disadvantages and Limitations of MF ..................................... 127 5.3.3 Typical Applications of MF ............................................... 127 5.4 Cellulose Ester ................................................................ 127 5.4.1 Advantages of Cellulose Ester ............................................. 127 5.4.2 Disadvantages and Limitations of Cellulose Ester ...........................128 5.4.3 Typical Applications of Cellulose Ester ..................................... 128 5.5 Cyanate ...................................................................... 128 5.5.1 Advantages of Cyanate ................................................... 131 5.5.2 Disadvantages and Limitations of Cyanate .................................131 5.5.3 Typical Applications of Cyanate ........................................... 132 5.6 Epoxy (EP) ................................................................... 132 5.6.1 Advantages of Epoxy..................................................... 134 5.6.2 Disadvantages and Limitations of Epoxy ................................... 134 5.6.3 Typical Applications of Epoxy ............................................ 134 5.7 Phenol Formaldehyde (Phenolic, PF) ............................................ 135 5.7.1 Advantages of Phenolics ................................................. 137 5.7.2 Disadvantages and Limitations of Phenolics ................................ 137 5.7.3 Typical Applications of Phenolics ......................................... 138 5.8 Polybutadiene (PB) ............................................................ 138 5.8.1 Advantages of PB ........................................................ 138 5.8.2 Disadvantages and Limitations of PB ...................................... 138 5.8.3 Typical Applications of PB ............................................... 139 5.9 Bismaleimide (BMI) ........................................................... 139 5.9.1 Advantages of BMI ...................................................... 140 5.9.2 Disadvantages and Limitations of BMI .................................... 140 5.9.3 Typical Applications of BMI .............................................. 140 5.10Unsaturated Polyester (UP) ..................................................... 141 5.10.1 Advantages of UP ....................................................... 143 5.10.2 Disadvantages and Limitations of UP ...................................... 143 5.10.3 Typical Applications of UP ............................................... 144 5.11Polyimide (PI) ................................................................ 144 5.11.1 Advantages of PI........................................................ 146 5.11.2 Disadvantages and Limitations of PI....................................... 146 5.11.3 Typical Applications of PI................................................ 146 5.12Polyxylene .................................................................... 147 5.12.1 Advantages of Polyxylene ................................................147 5.12.2 Disadvantages and Limitations of Polyxylene ............................... 147 5.12.3 Typical Applications of Polyxylene ........................................ 147 5.13Polyurethane (PUR) ........................................................... 148 5.13.1 Advantages of PUR ...................................................... 151 5.13.2 Disadvantages and Limitations of PUR .................................... 151 5.13.3 Typical Applications of PUR .............................................. 152 5.14 Silicone (SI) ..................................................................152 5.14.1 Advantages of SI ........................................................ 153 5.14.2 Disadvantages and Limitations of SI ....................................... 153 5.14.3 Typical Applications of SI ................................................ 154 5.15Urethane Hybrid .............................................................. 154 5.15.1 Reaction Injection Molding (RIM) ........................................ 155 5.15.2 SRIM Processing ........................................................ 155 5.15.3 Advantages of Urethane Hybrid ........................................... 156 5.15.4 Disadvantages and Limitations of Urethane Hybrid ......................... 157 5.15.5 Typical Applications of Urethane Hybrid ................................... 157 5.16Vinyl Ester (BPA) .............................................................. 157 5.16.1 Advantages of this Process................................................ 160 5.16.2 Advantages ofVinyl Ester ................................................ 160 5.16.3 Disadvantages and Limitations ofVinyl Ester ............................... 160 5.16.5 Typical Applications ofVinyl Ester ........................................ 160 Selected References ................................................................... 161
Library of Congress Subject Headings for this publication:
Polymers -- Industrial applications -- Handbooks, manuals, etc.