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Conference Proceedings

ENHANCED DIELECTRIC LIFETIME OF MULTILAYERED PC/PVDF-HFP FOR CAPACITOR APPLICATIONS
Z. Zhou, M. Mackey, E. Baer, May 2012

The dielectric lifetime and breakdown mechanism of PC/PVDF-HFP systems were studied under constant DC field. The 32 L and 256 L PC/PVDF-HFP systems show two orders of magnitude longer dielectric lifetime compared with blend system of PC/PVDF-HFP. It is attributed that the layered structure can impede the breakdown process by deflecting the fracture propagation pathway. The DC resistivity of PC/PVDF-HFP systems was measured and correlates well with the dielectric lifetime in PC/PVDF-HFP system, which implied that the DC resistivity is also an important factor contributing to the enhancement of dielectric lifetime of the layered films.

COMPARATIVE THERMAL AND RHEOLOGICAL STUDY OF AROMATIC AND ALIPHATIC POLYAMIDE NANOCOMPOSITES AND FILMS
Matyam Fereydoon, Seyed H. Tabatabaei, Abdellah Ajji, May 2012

In this study, thermal and rheological properties of polyamide 6 (PA6), poly (m-xylene adipamide) (MXD6) and their commercial nanocomposites (4 wt.% clay) were studied. Dynamic rheological experiments were carried out for both neat resins and corresponding nanocomposites at different temperatures. Rheological measurements were conducted using a strain-controlled rheometer. Crystallinity and thermal transitions of the materials are established via both DSC and XRD techniques. Oxygen transmission rates were also measured and normalized by the films thickness.

RAPID PERMEATION MEASUREMENT SYSTEM FOR THE GAS PERMEABILITY OF FILMS
Julia Botos, Martin Bastian, Peter Heidemeyer, Karsten Kretschmer, Thomas Hochrein, May 2012

Gas permeation measurements performed on films according to the standard take a long time. We present a method with helium for a quick measurement with measuring times of only a few minutes. This allows an accelerated iterative development of new formulations for films directly at the production line and the monitoring of the barrier properties for quality control. The investigations show a good correlation between the results of the accelerated and standardized tests.

IMPROVING FILM DIE FLOW UNIFORMITY USING OPTIMIZATION METHODS COUPLED WITH FINITE ELEMENT CFD ANALYSIS
Patrick C. Lee, Laura Dietsche, Joseph Dooley, Sumeet Parashar, May 2012

This study shows how the flow uniformity from a film die can be improved by modifying the geometry of the die using a three dimensional finite element optimization technique. In this study, various optimization strategies were used to optimize the geometry to meet the desired objectives of uniform flow at the die exit and minimal pressure drop. Finite element simulations using the numerically optimized geometry predict a more uniform flow than simulations using the baseline geometry. However, some of the numerically optimized die geometries obtained in this study would be impractical to fabricate. Thus we see the power of CFD-based optimization methods to lead towards potentially better performing options; but we also see the necessity of understanding both the die design technology and fabrication techniques in order to analyze the practicality of the proposed optimized solutions. This knowledge can be used to redirect the optimization towards more practical solutions through the use of geometric constraints.

COMMERCIALIZATION ROADMAP OF BIOPOLYMERS & BIOCOMPOSITES
Sam McCord, Mike Parker, May 2012

The advent of new base raw materials composed of recycled post consumer/post industrial plastics combined with organic bio fibers that up to now had no value added/sustainable use, has created a global market for a new classification of materials, Bio Fiber Composites. Fundamentally, these composites reduce the hydrocarbon content, (oil) replaced with natural fillers in the form of organic “renewable.” This family of materials is best suited to replace pure polymers, and drives the green, sustainable shift of achieving a balance of physical and mechanical properties to produce the goods and components needed across the complete product landscape. Any product that is injection molded, extruded, thermoformed, or rotationally molded today, can be replaced with a natural organic filled BioComposites Materials. MCG BioComposites, LLC has been formed to supply this place in the industry. This paper will demonstrate the uses and commercial applications for various biomasses, i.e., corn cob fiber, flax fiber and wheat starch.

MODELING AND SIMULATION OF THERMALLY AND FLOW INDUCED CRYSTALLIZATION OF SEMI-CRYSTALLINE POLYMERS
Yue Mu, Guoqun Zhaoi, Xianghong Wu, May 2012

The simulation of thermally and flow induced crystallization behavior of semi-crystalline polymers is of great engineering significance in polymer processing like injection, blow molding and extrusion. However, its key technology for practical application remains to be difficult. In the study, the mathematical model of three- dimensional thermally and flow induced crystallization of polymer melts obeying Phan-Thien and Tanner (PTT) constitutive model is established. A penalty finite element/finite difference method is introduced to solve the nonlinear governing equations. The computation stability is improved by using the discrete elastic-viscous split stress (DEVSS) algorithm incorporating the streamline upwind scheme. A modified Schneider’s approach is employed to discriminate the relative roles of the thermal and the flow state on the crystallization phenomenon. Two driving causes for the crystallization of polypropylene in extrusion process including the thermal and the flow state are investigated. Both the crystalline distribution and crystalline size of polypropylene are obtained based on the proposed mathematical model and numerical scheme.

MOLD FLOW ANALYSIS OF MOBILE PHONE CASE MADE BY TPS (THERMOPLASTIC STARCH)/(PC/ABS)
Sheng-Ju Liao, Shihn-Juh Liou, Chih-Jen Chang, May 2012

Mold flow analysis of mobile phone case was used in this study to evaluate the intrinsic characteristics of biomass materials how to influence the parameters of injection mold process and the outward appearance of product. Two materials were selected, one is TPS/(PC/ABS) biomass-based material developed by ITRI, and the other is commercial petrochemical plastic PC/ABS. In addition to evaluate the difference between these two materials in the injection mold process and dimensional stability, carbon emissions during this injection mold process were also calculated. Above results will show advantages and shortcomings of this newly developed TPS/(PC/ABS) biomass-based material.

CHAIN EXTENSION OF RECYCLED POLYAMIDES : HOW TO INCREASE THE AMOUNT OF RECYCLED PA IN THE AUTOMOTIVE INDUSTRY
Elodie Gaouyat, May 2012

The present work attempted to implement reactive compatibilisation of blends of recycled engineering plastics, more particularly the case of recycled PA66 contaminated by recycled PA6. Low molecular weight, high Tg Styrene-Maleic Anhydride copolymers were tested as chain extenders / compatibilizers. It appeared that the addition of 2% by weight of SMA to an incompatible system of recycled PA6 and PA66 improved both ductility and impact performance by factors of at least 10 and 1.5 respectively. Moreover, high Tg SMA improved performances at elevated temperature, partly due to its ability to effectively crosslink but also because of its inherent heat resistance.

THICKNESS PROFILE EFFECTS ON THE BUILD-UP PROCESS OF FILM-ROLLS IN THE WINDING PROCESS
Johannes Wortberg, Felix A. Heinzler, May 2012

A high percentage of today’s blown-film-extrusion-machines is equipped with a reversing system. The reversing draw-up unit is supposed to rearrange tolerances of the thickness profile on the film-roll within the winding process. Most process setups in the blown-film-extrusion production have a standardized reversing speed or do not use the reversion. A new simulation model developed at the University of Duisburg-Essen can show the critical effects of these setups in the build-up of film rolls and links them to detected defects in today’s production.

CARBON NANOFIBER/POLYETHYLENE NANOCOMPOSITES FOR ESD AND EMI APPLICATIONS
Mohammed Al-Saleh, Uttandaraman Sundararaj,, May 2012

Vapor grown carbon nanofiber (VGCNF) / High density polyethylene (HDPE) conductive nanocomposites were prepared by melt mixing. The nanocomposites electrical and electromagnetic (EMI) shielding properties were studies as function of filler concentration. The electrical resistivity of 1.5 vol% VGCNF/HDPE nanocomposite was 105 Ohm-cm indicating that this nanocomposite is suitable for electrostatic discharge (ESD) protection applications. In the 0.1-1.5 GHz frequency range, 2 mm thick plates made of HDPE filled with 5 vol% VGCNF showed an EMI SE of 20 dB, this level of attenuation is adequate for laptop and desktop computers shielding.

FEA SIMULATION STUDY ON DESIGN OPTIMISATION OF MOULD FEEDING SYSTEM FOR PRECISION MICRO MOULDING OF POLYMERIC MICROFLUIDIC CHIP
Ge Chen, Jianhong Zhao, Szu Hui Lim, Sin Min Low, Feng Lin Ng, May 2012

Moulding of micron features is a pre-requisite for manufacturing of polymeric microfluidic chips. The final quality of moulded microfluidic chips could be affected by the various types of design factors in a mould feeding system. In this paper, two design factors, notably the gate location and gate type, are extensively evaluated through finite element analysis (FEA) simulation to investigate how the melt flow behaviour of polymer could affect the quality of moulded microfluidic chips.

CROSS-LINKING OF HYDROGEL WITH A NEW WATER-SOLUBLE AGENT, DIISOSORBIDE BISEPOXIDE
Herman Suwardie, Bhavita Joshi, Eleanor Ojinnaka, William B. Hammond, George C. Collins, May 2012

Cross-linking of polymeric biomaterials has increased in interest over the last 5-10 years. One category of biomaterials is hydrogel, a chemically cross-linked network that swells when immersed in water. Dextran, a polysaccharide, can be crosslinked to form hydrogels that have found application as tissue scaffolds and delivery devices. In this study, dextran is cross-linked with diisorbide bisepoxide, a water soluble chemical cross-linker. The gelation temperature and gel time will be monitored using oscillatory rheometer.

NEW FULL DRY SYSTEM DEVELOPED FOR BI-ORIENTED PIPES BRINGS EXCELLENT OPPORTUNITIES FOR PVC-O
Ignacio Muñoz de Juan, May 2012

Systems that today exist for PVC-O piping are clearly defined in two: in-batch and in-line systems. In batch systems, stable, flexible, allowing high orientation degree and raw material savings, are at the same time not much efficient in terms of energy, labour, output, and are highly penalized by internal logistics. The development of new systems, based on air, improves dramatically energy & labour savings, speed and efficiency, allowing the integration in a standard extrusion line. The result is a stable and reliable process, highly profitable, working on a continuous way and getting efficiency of an in-line process.

THERMALLY BUTT-FUSED PVC PIPE AND THE EXPANSION OF TRENCHLESS INSTALLATIONS IN THE WATER AND WASTEWATER APPLICATIONS
Tom Marti, Richard Botteicher, May 2012

The application of thermal butt-fusion joining technology to polyvinylchloride (PVC) piping has had a major impact on the waterworks market over the last seven years. The combination of a familiar, industry standard piping material with a joining method that lends itself to cutting edge trenchless installation methods has seen rapid expansion in application and use in the water and wastewater industries. Trenchless methods that involve the installation of a new pipeline, or ‘whole pipe replacement,’ include horizontal directional drilling (HDD), sliplining, and pipe bursting methodologies. These methods are characterized by the installation of a new pipeline or conduit that does not derive pressure capacity, strength, or design life from any previously installed or “host” infrastructure. Polyvinylchloride (PVC) pipe with the use of butt-fused PVC pipe technology has made great strides in these applications, due to its high tensile strength capacity, high hydrostatic design basis, good chemical compatibility, and abrasion resistance. The use of butt-fused PVC pipe has expanded the capabilities of thermoplastic pipe within these methodologies, allowing greater pull-in lengths, depths, and pressure capacities to be achieved. This paper will discuss the materials and technology that are allowing for this expansion as well as highlight the direct impact on the installation methodologies through several recent case study examples. Case studies will include a record setting horizontal directional drill for a water transmission main installation; a large diameter force main rehabilitation through the use of sliplining; and a pipe bursting replacement program for potable water distribution mains, all in North America. This information will illustrate the innovative nature of this joining methodology, flexibility and range of the current whole pipe replacement offerings, and demonstrate how they are growing in use as end users benefit from this unique application of PVC pipe.

MODELING AND ANALYSIS OF CURE KINETICS OF ALIPHATIC EPOXY RESIN WITH AND WITHOUT DIFFUSION
Nora C. Restrepo-Zapata, Tim A. Osswald, Juan Pablo Hernández-Ortiz, May 2012

The curing reaction of an aliphatic epoxy resin is modeled from differential scanning calorimetry (DSC), using a methodology proposed by Hernandez-Ortiz and Osswald. The kinetics is represented by modified Kamal-Sourour model which includes the diffusion reaction control; the modeling uses a non-linear regression method and DiBenedetto’s equation for the diffusion part of reaction. The kinetic fitting methodology uses dynamic and isothermal differential scanning calorimetries for two different accelerator concentrations

NUMERICAL VISUALIZATION ON COOLING MECHANISM FOR CONFORMAL COOLING SYSTEM IN INJECTION MOLDING
Fu-Hang Hsu, Hung-Chou Wang, Wei-Da Wang, Chao-Tsai Huang, Rong-Yeu Chang, May 2012

In an injection molding process, cooling time usually dominates the whole cycle time. Therefore, decreasing cooling time can help save manufacturing cost. Cooling system design is one of a crucial factor to reduce cooling time. However, by using traditional molding manufacturing method, cooling system layout is restricted. For cavities with greater curvature, the distance between cooling channels and cavity may vary throughout the part. This causes local heat accumulation and hence worse product quality. By using some non-conventional methods such as laser sintering and 3D printing techniques, cooling channels can get closer to the cavity surface than using traditional method. The current study uses a true three dimensional simulator to predict the injection molding process and product deformation. The results from a conventional and a conformal cooling design were compared. The results also show flow behavior inside cooling channels which provide important indices for cooling efficiency improvement. With a shorter cycle time and better product quality, conformal cooling has a great potential in injection molding industry.

COMPOSITION-OPTIMIZED SYNTHETIC GRAPHITE/POLYMER NANOCOMPOSITES
Ehsan Bafekrpour, George P. Simon, Minoo Naebe, Jana Habsuda, Chunhui Yang, Bronwyn Fox, May 2012

In this study the optimization design, fabrication and characterization of synthetic graphite/phenolic nanocomposites are performed. The composition of synthetic graphite/phenolic nanocomposites was controlled across the thickness by stacking eight homogeneous layers containing 0, 5, 10, and 20wt% synthetic graphite in different sequences. Four compositional gradient patterns, as well as a homogenous nanocomposite, with the same geometry and synthetic graphite content, were fabricated to investigate the optimized design for thermomechanical properties. Results show that nanocomposites with a high concentration of synthetic graphite on the surfaces and neat resin at the center have the best thermomechanical and viscoelastic properties.

LASER WELDING OF INCOMPATIBLE SEMI-CRYSTALLINE THERMOPLASTICS BE MEANS OF INTERMEDIATE LAYERS
Christian Hopmann, Mathias Weber, May 2012

The weldability of dissimilar thermoplastics is restricted except for a few combinations using conventional welding processes for thermoplastics. Among these processes laser transmission welding is a relative new and innovative technology. The so called intermediate layer method is a new variant of the laser transmission welding which allows joining transparent plastic parts. This paper details with the enhancement of the intermediate layer method that leads to an improved weldability of dissimilar thermoplastics. Within the scope of a current research project the weldability of polypropylene and polyamide 6 using multi?layer films with a layer of an adhesion promoter can be demonstrated. Thereby, the film thickness is of particular significance.

SIMULATING THE PARISON GEOMETRY IN EXTRUSION BLOW MOLDING WITH VISCOELASTIC MATERIAL MODELS
Christian Hopmann, Walter Michaeli, Michael Aulbert, Christian Windeck, May 2012

In this study the molding step in extrusion blow molding is simulated using different viscoelastic material models. The material parameters are determined and material, throughput, temperature as well as the die geometry are varied during simulations. The quality of the parison geometry prediction is evaluated by comparing the computed results of the parison geometry with experimental data. In addition, an evaluation of the suitability of the different viscoelastic material models is performed.

EFFECTS OF MOLECULAR ORIENTATIONS AND RESIDUAL STRESSES ON THE ENVIRONMENTAL STRESS CRACKING STRESS CRACKING RESISTANCE OF POLYCARBONATE
Christian Hopmann, Markus Brinkmann, Nikolai Borchmann, Andre Potthoff, May 2012

Environmental stress cracking is the most common failure reason of plastic parts. The influence of the processing conditions has been investigated in a previous research project at IKV. Yet, it was not clear if these effects can be correlated with the molecular orientations or the residual stresses. Therefore the effects of molecular orientations and residual stresses on the ESC?resistance are analyzed. The results of these investigations are discussed in?depth.







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