Scrap, thermoplastic

Thermoplastics consist of long chain molecules that are produced from small molecules (called mers) by a polymerization process. An example of the formation of a typical polymer is given in Fig. 9.2 where polyethylene is produced from the monomer ethylene by application of heat, pressure, and a catalyst. When the resulting polymer is cooled, it solidifies. When reheated, a thermoplastic such as this will become liquid again. Due to this reversible liquid-solid conversion, scrap thermoplastic material may be recycled. Other thermoplastics are polypropylene, polyvinylchloride (PVC), polystyrene, polytetrafiuoro-ethylene (PTFE), polyesters, polycarbonates, nylons, cellulosics. 

Fabrication of polymeric materials normally occurs at elevated temperatures and often by the application of pressure. Thermoplastics are formed above their glass transition temperatures, if amorphous, or above their melting temperatures, if semicrystalline. An apphed pressure must be maintained as the piece is cooled so that the formed article retains its shape. One significant economic benefit of using thermoplastics is that they may be recycled scrap thermoplastic pieces may be remelted and re-formed into new shapes. 

Because high oxygen-barrier plastics are incompatible with other thermoplastics, extmdable adhesives must be extmded between the layers. Scrap can be included within the multilayer stmcture, provided an extmdable adhesive is incorporated. 

Although it would be desirable to recycle laminate scrap, this has been difficult because of its thermoset nature. However, a 1993 patent (18) suggested a means whereby scrap consisting of cellulose, thermoset resins, and partially reacted resins can be ground to a powder which is used as a filler in a thermoplastic resin. The filled thermoplastic resin is then used for mol ding of various articles. 

As with all thermoplastic elastomers, the copolyesterethers can be processed as thermoplastics. They are linear polymers and contain no chemical cross-links, thus the vulcanisation step needed for thermosetting elastomers is eliminated and scrap elastomer can be re-used in the same process as virgin material (176—180). 

The thermoplastic or thermoset nature of the resin in the colorant—resin matrix is also important. For thermoplastics, the polymerisation reaction is completed, the materials are processed at or close to their melting points, and scrap may be reground and remolded, eg, polyethylene, propjiene, poly(vinyl chloride), acetal resins (qv), acryhcs, ABS, nylons, ceUulosics, and polystyrene (see Olefin polymers Vinyl polymers Acrylic ester polymers Polyamides Cellulose ESTERS Styrene polymers). In the case of thermoset resins, the chemical reaction is only partially complete when the colorants are added and is concluded when the resin is molded. The result is a nonmeltable cross-linked resin that caimot be reworked, eg, epoxy resins (qv), urea—formaldehyde, melamine—formaldehyde, phenoHcs, and thermoset polyesters (qv) (see Amino resins and plastics Phenolic resins). 

Multiblock Copolymers. Replacement of conventional vulcanized mbber is the main appHcation for the polar polyurethane, polyester, and polyamide block copolymers. Like styrenic block copolymers, they can be molded or extmded using equipment designed for processing thermoplastics. Melt temperatures during processing are between 175 and 225°C, and predrying is requited scrap is reusable. They are mostiy used as essentially pure materials, although some work on blends with various thermoplastics such as plasticized and unplasticized PVC and also ABS and polycarbonate (14,18,67—69) has been reported. Plasticizers intended for use with PVC have also been blended with polyester block copolymers (67). 

There are two approaches to the combining of scrap rubber and plastics. The initial interest was to use the cmmb in minor proportions to toughen the plastics improving impact strength and reduce the overall cost. A more recent interest is to develop a type of thermoplastic elastomer (TPE) wherein the mbber is the major component bonded together by thermoplastics, which can be processed and recovered as thermoplastics. 

Thermoplastic elastomeric compositions from reclaimed NR and scrap LDPE with 50 50 mbber/plastic ratio shows good processability, ultimate elongation, and set properties. Polymer blends of reclaimed mbber and LDPE exhibit higher viscosity over the range of shear rate at various temperatures compared to virgin NR-LDPE blends due to the influence of filler present in the reclaimed mbber (Eigure 38.7) [109]. 

When a thermoplastic polyurethane elastomer is heated above the melting point of its hard blocks, the chains can flow and the polymer can be molded to a new shape. When the polymer cools, new hard blocks form, recreating the physical crosslinks. We take advantage of these properties to mold elastomeric items that do not need to be cured like conventional rubbers. Scrap moldings, sprues, etc. can be recycled directly back to the extruder, which increases the efficiency of this process. In contrast, chemically crosslinked elastomers, which are thermosetting polymers, cannot be reprocessed after they have been cured. 

You 11 recall that thermosets are polymAs that have lots of cross-linking. The molecules are three-dimensional, rather than two. More importantly, once the cross-linking bonds are in place, the polymer becomes rigid and hard. Put another way, once the thermoset occurs, it is irreversibly set. That s the difference between thermosets and thermoplastics. The latter can be remolded and reshaped the former cannot. When you sweep up the scrap material around the molding/extruding machines that handle thermosets, you throw it away. 

During the manufacture of appliance cabinets, a thermoplastic synthetic resin sheet, usually made of PS, is either co-extruded with a barrier layer or laminated to a barrier layer to make the inner liner. To successfully recycle the trim or scrap, the protective polymer film... 

Health and Safety Issues. Polyesterether elastomers derived from dimethyl terephthalate, butanediol, and Ptmeg are not hazardous according to the published Materials Safety Data Sheets (MSDS) for this elastomer. Polymers of a similar structure containing isophthalic acid are also not considered hazardous. For other copolymer elastomers, the MSDS put out by suppliers should be consulted by potential users before evaluation. One environmental advantage of thermoplastic elastomers of this type is that they are melt-reprocessible and thus scrap and off-specification material and even obselete parts can be easily recycled. Up to 25% by weight of recycled material can be incorporated (see Recycling, plastics). 

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