Overview
A plastic is a material that contains a polymerized organic substance of large molecular weight as an essential ingredient, is solid in its finished state, and at some stage in its manufacture or its processing into finished articles can be shaped by flow. The plastic industries have developed and grown then, since their discovery. Plastics can be used in various applications because of their toughness, water resistance, excellent resistance to corrosion, ease of fabrication, and remarkable color range.
History
The development of commercial phenolic resin in 1909 by Baekland was the start of the synthetic plastic industry. His discovery stimulated the search for other plastics. The first plastic of industrial significance was cellulose nitrate (Celluloid) and was discovered about the middle of the nineteenth century. It was first used in 1869 by Hyatt who was searching for an ivory substitute.
Classification
Thermosetting plastics are processed by heat curing to produce an infusible or insoluble product. Thermoplastics are processed by heating to soften them and cooling to harden them. On the basis of derivation, they may also be grouped as natural resins, cellulose derivatives, protein products, and synthetic resins.
Polyurethanes
Insulation, foam inner liners for clothing, rocket fuel binders, elastomers, adhesives
Polyethers
housewares
Polypropylene Housewares, medical equipment (can be sterilized), appliances, toys, electronic components, tubings and pipes, fibers and filaments, coatings
translucent floor tiles, windows, and canopies Polystyrene Insulation, pipe, foams, cooling towers, thin-walled containers, appliances, rubbers, automotive
Standard Symbols
Raw Materials
Monomers: vinyl chloride, ethylene, propylene and similar simple hydrocarbons Chemical intermediates : phenol, formaldehyde, hexamethylenetetramine, phthalic anhydride, methyl acrylate and methacrylate Other raw materials: plasticizers, fillers, and reinforcements are also added to alter the properties of the plastic products.
Manufacturing Processes
Bulk Polymerization
is carried out in the liquid or vapor state. The monomers and activator are mixed in a reactor and heated or cooled as needed.
Solution Polymerization
is used when the exothermic heat is too great to be controlled in bulk polymerization. The monomer and initiator are dissolved in a nonreactive solvent which serves to slow the reaction and thus moderate the heat given off.
Manufacturing Processes
Suspension Polymerization
is the process where the monomer is suspended in water by agitation. stabilizers (i.e. talc, fullers earth, and bentonite) are added to stabilize the suspension and prevent polymer globules from adhering to each other.
Emulsion Polymerization
is similar to suspension polymerization but the monomer is broken up into droplets that form aggregates called micelles. The monomer is on the interior of the micelles, and the initiator is in the water. Soap or another emulsifying agent is used to stabilize the micelles.
Polyethylene
It is the first and the largest in production of polyolefin plastic. High-density polyethylene (HDPE), produced by low-pressure methods, is used mainly for blowmolded containers and injection-molded articles and pipe. Low-density polyethylene (LDPE), produced by high-pressure methods, is used mainly for plastic films.
Polyethylene
Classification
According to Spinning Procedures
Melt spinning involves pumping molten polymer through capillaries or spinnerets and the polymer streams that emerge are solidified by quenching in cool air. In dry spinning, the polymer is dissolved in a suitable organic solvent. The solution is forced through spinnerets and dry filaments are formed upon evaporation of the solvent. Wet spinning involves spinning of a solution of polymer and coagulation of the fiber in a chemical bath.
Overview
Fibers were originally of natural origin and were produced from wool, silk, cotton, flax, and similar materials. The first man-made fibers were made by Swan in 1883 when he squirted a solution of cellulose nitrate in acetic acid through holes. Fibers have three important general properties: length, crimp and denier.
Vinyon is the trade name of copolymers of 90% vinyl chloride and 10% vinyl acetate. Resistance to acids and alkalies, sunlight, and aging makes Vinyon useful in heat-sealing fabrics and clothing.
Multicomponent fibers
Multicomponent fibers have been prepared which possess superior properties to either component if spun alone. They correspond to better dyeability, permanent crimp, or silklike feel, etc.
Films
are made from different polymers such as polyesters, polyvinyl chloride, etc.
Nylon 6.6
Nylon 6.6 was the first all-synthetic fiber made commercially and opened up the entire field. It is the product resulting from the polymerization of adipic acid and hexamethylene diamine.
Raw Materials
The raw materials for fiber production are just the same as in plastics production and will depend on the type of material the fiber is made up of.
For the production of nylon yarn, however, the raw materials cited are adipic acid and hexamethylene diamine (hexa). Utilities such as steam and water will also be used.
The filaments are solidified by air and passed in a bundle through steamhumidifying chamber.
Melt Spinning
Reference Austin, G.T. Shreves Chemical Process Industries (5th Ed). New York: McGrawHill, Inc., 1984.