1. Q6 Plastics
Plastics
Any Substance that can be shaped by moulding in the solid state by pressure can be termed plastic.

2. Plastics Plastics can be divided into three categories:
Natural Plastic – Amber, animal horn, Natural rubber and Shellac (produced by insects in trees).
Modified Natural Plastic – Cellulose and Casein (comes from cows milk)
Synthetic Plastic – Manmade plastic, play an important role as engineering material

3. Plastics
Composition and Structure of plastic: All plastics are organic, all substances exist in the form of molecules, where the atoms are bound together by strong forces of attraction.
Example: A molecule of gas methane consists of one carbon atom and four hydrogen atoms.

4. Plastics
Monomer: This is a single molecule of a compound capable of reacting with other similar molecules or with molecules of another compound to form larger molecules. A monomer is made up of two similar mers joined together.
Ethylene Molecule: Each mer being a carbon atom linked to two hydrogen atoms.

5. Plastics
Polymer: A polymer is a long chain molecule resulting from the addition of many monomers. For Ethylene, the bonds between the carbon atoms are easily broken, allowing two or more similar monomers to combine giving a larger molecule.

6. Plastics
When various ethylene monomers are added together the resulting polymer is called polyethylene. The process of linking the various similar monomers together is known as Additional Polymerisation.

7. Plastics
Co-Polymerisation: When two or more different monomers are polymerised, the product is known as a co-polymer.
The properties of a co-polymer are different and often used to produce a lot of substances in comparison to those of polymers.

8. Plastics
Crystalline and Amorphous Polymers: This refers to the arrangement of the molecular chains that form the polymer.
In some parts molecular chains are aligned in parallel rows – Crystalline (ordered arrangement)
In other parts of the polymer the chains can be disordered – Amorphous.
Crystalline
Amorphous.

9. Plastics
Thermoplastic Polymer: These materials can be softened and re-soften indefinitely by the application of heat and pressure. When thermoplastics harden on cooling, they produce chains of great length. The chains produced can either be Linear or Branched.

10. Plastics

11. Plastics
Branched Chains: Some materials have branched chains. The branches in one chain can interfere with the branches of another and this forces them apart. The further apart the chains the weaker the forces of attraction between them and the more flexible the material.
Linear Chains: All of the chains are quite separate from each other. These chains are held together by weak forces of attraction, known as Van der Waals forces. Upon heating the forces, break down thus allowing the molecules to slip past each other and allowing plastic to be melted.

12. Plastics Thermoplastic Properties:
Thermoplastic materials are glassy, rubbery depending on temperature.
Soften on heating – easily shaped
Poor temperature resistance
Very Flammable

13. Plastic

14. Plastics
Thermosetting Polymer: These are produced from Condensation polymerisation. These types of polymers cannot be softened and reshaped once set. They are harder, stronger and more brittle than thermoplastics. This is because the chains have cross links. These cross links formed tend to prevent the movement of the various chains.

15. Plastics Properties of Thermosetting Plastics
Harden on initial heating, cannot be softened again.
Cross links formed.
The polymers are rigid solids.
Cannot be re-cycled once moulded.
Good temperature resistance
Not very flammable.

16. Plastics
Elastomers: These are polymers that have the property of high elasticity. They can stretch up to ten times there original size when a tensile force is applied, and will return to its original size once it is removed. They have an amorphous structure and a good example is rubber.

17. Plastics
Vulcanisation: The addition of sulphur to the rubber produces cross-links. The end result is that the springy rubber molecules become cross-linked to a greater extent. This makes the bulk material harder, much more durable and also more resistant to chemical attack.

18. Plastics - Definitions
Plasticisers: Are used to soften the plastic and put it in better condition for moulding. This plasticiser may be liquid, which disperses between the chains.
Fillers: Used to improve the tensile and impact strength of plastics.
Catalysts: These are called accelerators, they increase the speed of a chemical reaction.
Promoters: A substance added to improve the performance of the catalysts.
Inhibitors: A substance that will reduce the efficiency of a catalyst.

19. Plastics The Processing of Plastic Materials: Compression Moulding
When plastic materials leave the manufacturers (as powder, pellets etc.), they are taken to be converted into a usable workable material, from which an article or component may be produced with the help of machinery.
Compression Moulding
Injection Moulding
Extrusion
Blow Moulding
Vacuum Forming
Calendering
Spreading
Laminating

20. Q6. Plastic Processing Compression Moulding Extrusion Calendering
Injection Moulding
Blow Moulding
Vacuum Forming
Compression Moulding
Calendering
Strip Heating
Rotational Moulding

21. 1. Extrusion

22. Extrusion
Continuous process  used to produce both solid and hollow products that have a constant cross-section. E.g. window frames, hose pipe, curtain track, garden trellis.
Thermoplastic granules are fed from a hopper by a rotating screw through a heated cylinder.
The tapered screw compacts the plastic as it becomes elasticised. The die which is fitted to the end of the extruder barrel  determines the cross-section  of the extrusion.
Thicker cross-sections are extruded more slowly as more time is required  for the initial heating and subsequent cooling of the larger quantities of material which are involved. As the extrusion leaves the die it is cooled  by passing through a cooling trough (below) containing cold water.

23. Plastics
Components produced by Extrusion:

24. 2. Injection Moulding
Powder or granules from a hopper into a steel barrel with a rotating screw. The barrel is surrounded by heaters The screw is forced back as plastic collects at the end of the barrel .
Once a sufficient charge of  melted plastic has accumulated a hydraulic ram forces the screw forward injecting the thermoplastic through a sprue into the mould cavity.

25. Injection Moulding
Pressure is kept on the mould until the plastic has cooled sufficiently
for the mould to be opened and the component ejected.
Materials used
Normally thermoplastics are used in this process although a few thermosetting plastics can also be injection moulded.
Toy made from high impact polystyrene (HIPS).

26. Plastics
Components produced from Injection Moulding

27. 3. Blow Moulding
1. A hollow length of plastic, called a parison, is extruded down between the two halves of the mould.
2. The mould closes.

28. 4. Blow Moulding
3. Compressed air is blown into the inside of the parison which inflates it, pushing the soft plastic hard against the cold surfaces of the mould.
4. The mould is then opened the moulding ejected and the waste (called flash) is trimmed off with a knife.

29. Materials used in blow moulding
High density polyethylene (HDPE) and low density polyethylene (LDPE)  are both commonly used for blow moulding as are other types of thermoplastics. The thermoplastic used in blow moulding  needs to be more viscous (flow less easily) than that used for injection moulding as the parison must  retain its form before the mould closes around it.
Used extensively to make bottles and other lightweight , hollow parts

30. Plastics
Components produced by Blow Moulding:

31. 5. Vacuum Forming
2. Once the thermoplastic sheet is softened enough (reaches a plastic state) then air is blown in to raise  the sheet in a slight bubble before the platen is raised bringing the mould into contact with the plastic.
1. Mould is attached to a platen (support plate). The platen and mould are then lowered and a rigid thermoplastic sheet material is clamped onto an air tight  gasket and usually heated from above.

32. Vacuum Forming
3. trapped air  remaining between the platen and the heated plastic sheet is then evacuated by a vacuum pump. Atmospheric pressure acting over the top surface completes the forming process by pressing  the plastic sheet onto the mould.
4. Once the plastic sheet has cooled down to below it's freeze point the air flow is reversed to lift the forming off the mould and the mould lowered

33. Materials used in Vacuum forming
Many types of thermoplastics are suitable for vacuum forming. The most popular is High Impact Polystyrene (HIPS). It is relatively cheap, comes in a wide range of colours and is easy to form. This process is used to manufacture a variety of  products in thermoplastic materials. These products range in size from garden pond liners to food trays used in supermarkets.

34. Plastics
Components produced by Vacuum Forming:

35. 6. Compression Moulding
2. When  the two halves of the mould are  brought together the plastic material is forced under compression to flow rapidly around the cavity. heat from the platens causes the plastic to cure resulting in a permanent change in shape.
1. The mould is charged with a measured amount of powder or granules ready to be compressed. Sometimes plastic charge is first compacted into a shape called a preform.

36. Compression Moulding
The component is ejected from the mould and any excess material formed at edges (flash) is removed.
Materials used.
Typical thermosetting plastics used in compression moulding are urea formaldehyde and phenol formaldehyde.

37. Plastics
Components produced from compression moulding

38. 7. Calendering

39. Calendering
Involves rolling out a mass of premixed plastics material between large rollers to form a continuous and  accurately sized film.
The process begins with the ingredients being blended and fluxed in a mixing mill at approx.100°C. Nip rollers control the thickness of the sheet material can be gradually reduced in thickness. Rolls of semi-rigid PVC which will be used to manufacture transparent A4 folder 'pockets'.
Materials used
The main material used is PVC, others include ABS and cellulose acetate. PVC ranges from flexible to rigid and the final product is composed of a number of basic materials which must be combined in a uniform mixture of measured ingredients. These ingredients include a resin of a specified molecular weight, stabilisers, lubricants, reinforcing materials, colorants and plasticisers.

40. 8. Rotational Moulding
1. A measured weight of thermoplastic is placed inside a cold mould. The mould is then closed  and moved into an oven chamber
2. heated to a temperature of C whilst being rotated around both vertical and horizontal axes. As it rotates the mass of powder at the bottom of the mould fuses and sticks to the mould surface.

41. Rotational Moulding
3. the mould moves into a cooling area  or chamber where it is cooled by air or water jets.
4. The hollow moulding can be removed as soon as it is cool enough to hold its shape.

42. Materials used
90% of rotational mouldings are made from polyethylene (PE), used mainly to manufacture hollow shaped products such as footballs, road cones and storage tanks up to 3m³ capacity.