Plastics, compounding methods

The attributes and properties of compounded plastics are applicable to many diverse applications. Although the focus of this chapter is the compounding of thermoplastic materials, many of the principles and comments also apply to thermoset polymers such as phenolics. The chapter will discuss compounding methods, the roles and challenges of additives, and techniques for introducing color to compounded plastics. 

WuT-S. Silane crosslinkable polyethylene compounds applications and manufacturing methods. Plastics Addit Compound [trade journal—Elsevier Ltd ] Novemher/Decemher 2007. 

The extraction of additives strongly adsorbed or chemisorbed on the polymer - filler matrix must be carefully observed by the analyst, as a change of the method of manufacture of, for example, the filler or in the method of compounding the plastic formulation, can... 

In this method, plastics are converted into low-molecular-weight compounds by degrading the pol3mier in the presence of microorganisms (Brandi et al., 1990). 

Most stndies on PVC nanocomposites have centered on plasticized formnlations (1,3). Relatively little in depth examination has been performed on rigid forms in particular. In addition little attention has been directed toward the effect of dry-blending compounding method on the performance of PVC nanocomposites. 

Many methods for the conversion of acid copolymers to ionomers have been described by Du Pont (27,28). The chemistry involved is simple when cations such as sodium or potassium are involved, but conditions must be controlled to obtain uniform products. Solutions of sodium hydroxide or methoxide can be fed to the acid copolymer melt, using a high shear device such as a two-roU mill to achieve uniformity. AH volatile by-products are easily removed during the conversion, which is mn at about 150°C. A continuous process has been described, using two extmders, the first designed to plasticate the feed polymer and mix it rapidly with the metal compound, eg, zinc oxide, at 160°C (28). Acetic acid is pumped into the melt to function as an activator. Volatiles are removed in an extraction-extmder which follows the reactor-extmder, and the anhydrous melt emerges through a die-plate as strands which are cut into pellets. 

In the calendering method, a PVC compound which contains plasticizers (qv) (60—120 phr), pigments (qv) (0—10 phr), fillers (qv) (20—60 phr), stabilizers (10—30 phr), and other additives, is kneaded with calender roUs at 150—200°C, followed by extmsion between clearance-adjusted roUs for bonding onto the substrate. This method is employed for products with thick PVC layers, ie, of 0.05—0.75 mm thickness. The main plasticizer used is di-2-ethylhexyl phthalate (DOP). For filler to reduce cost, calcium carbonate is mainly used. A woven or knit fabric made of cotton, rayon, nylon, polyester, and their blend fiber is used as substrate. For foamed vinyl-coated fabrics, the bonded materials are heated in an oven to decompose the foam-blowing... 

Commonly accepted practice restricts the term to plastics that serve engineering purposes and can be processed and reprocessed by injection and extmsion methods. This excludes the so-called specialty plastics, eg, fluorocarbon polymers and infusible film products such as Kapton and Updex polyimide film, and thermosets including phenoHcs, epoxies, urea—formaldehydes, and sdicones, some of which have been termed engineering plastics by other authors (4) (see Elastol rs, synthetic-fluorocarbon elastol rs Eluorine compounds, organic-tdtrafluoroethylenecopolyt rs with ethylene Phenolic resins Epoxy resins Amino resins and plastics). 

The concentration of acid impurities is an important indication of the quality of petroleum products and the purity of organic solvents, plasticizers, mineral oils, food fats, and polymers. Methods are used to detect organic acids in such compounds have many disadvantages the alkalimetry - low sensitivity, especially in the determination of weak acids, the extraction-photometric method is laborious, instmmental methods are expensive. In addition, most of methods are commonly unsuitable for direct analysis. 

Hard products may also be made by vulcanising rubber (natural or synthetic) using only about two parts of sulphur per 100 parts of rubber. In these cases either the so-called high-styrene resins or phenolie rubber compounding resins are ineorporated into the formulation. These compounds are processed using the methods of rubber technology but, like those of ebonite, the produets are more akin to plastics than to rubbers. Examples of the usage of these materials are to be found in battery boxes, shoe heels and ear washer brushes. 

After a brief historical review in Chapter 1 the following five chapters provide a short summary of the general methods of preparation of plastics materials and follow on by showing how properties are related to chemical structure. These particular chapters are largely qualitative in nature and are aimed not so much at the theoretical physical chemist but rather at the polymer technologist and the organic chemist who will require this knowledge in the practice of polymer and compound formulation. 

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