Contents

Contributors Preface xi

ix

Chapter 1. Thermoplastics
1.1 Introduction 1.2 Polymer Categories 1.3 Comparative Properties of Thermoplastics 1.4 Additives 1.5 Fillers 1.6 Polymer Blends References

1.1
1.1 1.4 1.79 1.79 1.82 1.83 1.85

Chapter 2. Thermosets, Reinforced Plastics, and Composites

2.1 Resins 2.2 Thermosetting Resin Family 2.3 Resin Characteristics 2.4 Resin Forms 2.5 Liquid Resin Processes 2.6 Laminates 2.7 Molding Compounds References

2.1
2.1 2.2 2.10 2.10 2.13 2.29 2.38 2.88

Chapter 3. Elastomeric Materials and Processes

3.1 Introduction 3.2 Thermoplastic Elastomers (TPEs) 3.3 Melt Processing Rubbers (MPRs) 3.4 Thermoplastic Vulcanizates (TPVs) 3.5 Synthetic Rubbers 3.6 Natural Rubber 3.7 Conclusion References

3.1
3.1 3.1 3.24 3.26 3.33 3.48 3.49 3.50

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Contents

Chapter 4. Plastic Additives

4.1 Introduction 4.2 Scope 4.3 Antiblock and Slip Agents 4.4 Antioxidants 4.5 Antistatic Agents 4.6 Biocides 4.7 Chemical Blowing Agents 4.8 Coupling Agents 4.9 Flame Retardants 4.10 Heat Stabilizers 4.11 Impact Modifiers 4.12 Light Stabilizers 4.13 Lubricants and Mold Release Agents 4.14 Nucleating Agents 4.15 Organic Peroxides 4.16 Plasticizers 4.17 Polyurethane Catalysts

4.1
4.1 4.2 4.2 4.6 4.12 4.16 4.19 4.23 4.26 4.36 4.41 4.46 4.49 4.54 4.58 4.62 4.66

Chapter 5. Processing of Thermoplastics

5.1 Material Concepts 5.2 Extrusion 5.3 Estrusion Processes 5.4 Injection Molding References

5.1
5.2 5.18 5.55 5.84 5.121

Chapter 6. Processing of Thermosets

6.1 6.2 6.3 6.4 6.5 6.6 6.7 Introduction Molding Processes Techniques for Machining and Secondary Operations Postmolding Operations Process-Related Design Considerations Mold Construction and Fabrication Summary

6.1
6.1 6.2 6.24 6.28 6.29 6.34 6.37

Chapter 7. Auxiliary Equipment

Section 1. Material Handling
7.1 Introduction 7.2 Raw Material Delivery 7.3 Bulk Storage of Resin 7.4 Bulk Resin Conveying Systems 7.5 Bulk Delivery Systems 7.6 Blending Systems 7.7 Regrind Systems 7.8 Material Drying 7.9 Loading Systems 7.10 System Integration

7.2
7.3
7.3 7.5 7.8 7.22 7.28 7.35 7.38 7.43 7.50 7.57

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Section 2. Drying and Dryers

7.11 7.12 7.13 7.14 7.15 7.16 7.17 7.18 7.19 7.20 Why Do We Dry Plastic Materials? Hygroscopic and Nonhygroscopic Polymers Drying Hygroscopic Polymers How Physical Characteristics of Plastics Affect Drying How Dryers Work Critical Dryer Components Monitoring Drying Conditions Drying System Configurations Gas or Electric? Handling Dried Material

7.63
7.63 7.65 7.66 7.71 7.72 7.77 7.85 7.89 7.93 7.94

Section 3. CAD, CAM, CAE

7.21 Introduction 7.22 Simulation and Polymer Processing 7.23 The Injection-Molding Process 7.24 History of Injection-Molding Simulation 7.25 Current Technology for Injection-Molding Simulation 7.26 The Changing Face of CAE 7.27 Machine Control 7.28 Future Trends References on CAD, CAM, CAE

7.99
7.99 7.101 7.104 7.106 7.109 7.123 7.126 7.129 7.131

Chapter 8. Design of Plastic Products

8.1 Fundamentals 8.2 Design Fundamentals for Plastic Parts 8.3 Design Details Specific to Major Processes References

8.1
8.1 8.49 8.79 8.116

Chapter 9. Finishing, Assembly, and Decorating

9.1 Introduction 9.2 Machining and Finishing 9.3 Assembly of Plastics PartsGeneral Considerations 9.4 Methods of Mechanical Joining 9.5 Adhesive Bonding 9.6 Welding 9.7 Recommended Assembly Processes for Common Plastics 9.8 Decorating Plastics References

9.1
9.1 9.2 9.16 9.17 9.35 9.70 9.80 9.91 9.105

Chapter 10. Coatings and Finishes

10.1 10.2 10.3 10.4 10.5 10.6 Introduction Environment and Safety Surface Preparation Coating Selection Coating Materials Application Methods

10.1
10.1 10.5 10.6 10.11 10.18 10.42

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Contents 10.7 Curing 10.8 Summary References 10.55 10.58 10.59

Chapter 11. Plastics Testing

11.1 Introduction 11.2 The Need for Testing Plastics 11.3 Diverse Types of Testing 11.4 Test Methods for Acquisition and Reporting of Property Data 11.5 Uniform Reporting Format 11.6 Misunderstood and Misused Properties 11.7 Costs of Data Generation Appendix 11.1 Selected ISO/IEC Standards/Documents Appendix 11.2 Selected ASTM Standards Appendix 11.3 List of Resources Appendix 11.4 Some Unit Conversion Factors References Suggested Reading

11.1
11.1 11.1 11.2 11.13 11.66 11.70 11.73 11.77 11.84 11.87 11.92 11.92 11.94

Chapter 12. Plastics Recycling and Biodegradable Plastics

12.1 Introduction 12.2 Overview of Recycling 12.3 Design for Recycling 12.4 Recycling of Major Polymers 12.5 Overview of Plastics Degradation 12.6 Natural Biodegradable Polymers 12.7 Synthetic Biodegradable Polymers 12.8 Water-Soluble Polymers 12.9 Summary References

12.1
12.1 12.14 12.22 12.24 12.71 12.80 12.92 12.97 12.99 12.100

Appendix A. Glossary of Terms and Definitions Appendix B. Some Common Abbreviations Used in the Plastics Industry Appendix C. Important Properties of Plastics and Listing of Plastic Suppliers Appendix D. Sources of Specifications and Standards for Plastics and Composites Appendix E. Plastics Associations
Index follows Appendix E

A.1

B.1

C.1

D.1 E.1