Multicomponent Polymeric Materials (eBook)

Professor Jin Kuk Kim is a senior professor of Department of Polymer Science of Gyeongsang National University, South Korea. Prof. Kim is one of the most regarded researchers in the field of Elastomer and Polymer Technology at global standard. Prof. Kim has published more than 100 research articles in the leading scientific journals during his research career. He has filled about 70 patents and edited 3 books on his credit. More than 50 national/international research projects have been completed under his investigation. He has been involved in the research on elastomer materials and composites for more than 25 years. His basic research includes, (i) high performance elastomer, (ii) thermoplastic Elastomer Gels/Soft Materials, (iii) electrospinning of nanofibers, (iv) polymeric biomaterial and its applications.Dr. Sabu Thomas is presently working as a Professor of Polymer Science & Technology & Hon. Director of Centre for Nanoscience and Nanotechnology, School of Chemical Sciences, Mahatma Gandhi University, India. His research area widely spreads from polymer to nanotechnology to biomaterials. His outstanding contributions to synthesis, characterization and applications of various polymeric nanomaterials, polymeric blends, fiber filled polymer composites, ageing and degradation of polymers, interpenetrating polymer systems and phase transitions are highly regarded and appreciated by global scientists community. Prof Thomas has h Index-67, Total Number of Publications- 593, Total Number of Citations-16500,Patents-4, Books- 30, PhD theses supervised- 64, Current PhD students-25, Projects -30, Funds Received- Rs.USD 3.7 million. He has been awarded and cited in the list of Most Productive Researchers in India, 5th Position, in 2008.Dr. Prosenjit Saha is an Assistant Professor in the Indian Institute of Engineering Science and Technology, Shibpur, India. He is a seasoned researcher with six years experiences on bio-based polymeric materials synthesis and characterization in India and South Korea with 14 peer-reviewed publications in leading International Journals. Based on the research outcomes, three patents have been filled (two Indian, and one US). Published journal articles were highly cited. One of them (published in Bioresources Technology) has been cited more than 63 times in last two years. Collaborate with broad spectrum of researchers from India, and South Korea. He has contributed as Reviewer of several peer reviewed journals such as J Appl Polym Sci., Carbohydr Polym., Bioresources, Construction and Building Materials, etc. His basic research area includes Synthesis, chemical modifications, and characterization of polymeric materials, Green synthesis of new-generation polyurethanes, Eco-friendly devulcanization of waste rubber composites, Electrospinning of nanofibers.

Contents 6
Contributors 8
Multicomponent Polymer Material Processing 11
1 Multi Component Materials 12
1.1 Introduction and Definition 12
1.2 Why Multicomponent Materials? 13
1.3 Recent Technologies 15
1.3.1 Extrusion 16
1.3.2 Extrusion Covering 16
1.3.3 Film Blowing 16
1.3.4 Calendering 17
1.3.5 Sheet Thermoforming 17
1.3.6 Blow Molding 17
1.3.7 Casting 18
1.3.8 Compression Molding 18
1.3.9 Transfer Molding 18
1.3.10 Injection Molding 19
1.3.11 Reaction Injection Molding 19
1.3.12 Coating 20
1.3.13 Rotational Molding 20
1.4 Future Trends for Multicomponent Material Fabrication 20
References 21
2 Design for Multicomponent Materials 22
2.1 Introduction 22
2.1.1 Fundamentals of Materials Processing and Design 23
2.1.1.1 Influence of Rheology on Design 29
2.1.1.2 Influence of Shear Rate on Design 32
2.1.1.3 Flow Performance and Design 33
2.1.1.4 Elasticity and Design 34
2.1.1.5 Molecular Weight and Design 35
2.1.1.6 Chemical Changes and Design 36
2.1.1.7 Physical State and Design 36
2.1.1.8 Other Parameters 36
2.1.2 Material Selection Approaches (Example) [43] 37
2.1.3 Case Studies 39
2.2 Summary 43
References 44
3 Design of Mold for Multicomponent Material 46
3.1 Introduction 46
3.2 Injection Mold for Multi-materials 49
3.2.1 Classification of Molding Process 49
3.2.2 Basic Mold Construction of Injection Mold 53
3.3 Injection Mold Design 55
3.3.1 Injection Mold 56
3.3.2 Two-Plate Mold 61
3.3.3 Mold Materials 65
3.3.3.1 Selection of the Mold Materials for the Application 66
3.3.3.2 Various Mold Materials 66
3.3.4 Other Considerations for Mold Design 72
3.3.5 Mold Design by Computer-Aided Design 79
3.3.5.1 Computer Aided Design System for Mold Design 80
3.3.5.2 Undercut 82
3.4 Summary 84
References 84
4 Injection Molding for Multicomponent Materials 88
4.1 Introduction 88
4.1.1 Basics of Injection Molding 88
4.1.2 Multi-materials Injection Molding 89
4.1.3 Multi-materials Injection Molding and Quality Control 90
4.2 Multi-materials Injection Molding 91
4.2.1 Multi-component Injection Molding 92
4.2.1.1 Co-injection Molding 92
4.2.1.2 Bi-Injection Molding 95
4.2.1.3 Interval Injection Molding 96
4.2.2 Multi-shot Injection Molding 97
4.2.2.1 Transfer Multi-shot Molding 98
4.2.2.2 Core Back Multi-shot Molding 98
4.2.2.3 Rotary Platen Multi-shot Molding 99
4.2.3 Over (Insert) Injection Molding 103
4.2.4 Others 106
4.3 Prospects on Multi-materials Injection Molding 109
4.3.1 Micro-powder Injection Molding 109
4.4 Summary 112
References 113
5 Extrusion of Multicomponent Product 117
Abstract 117
5.1 Introduction 117
5.2 Extrusion 117
5.3 Process and types of extrusion 118
5.3.1 Hot Extrusion 119
5.3.2 Cold Extrusion 120
5.3.3 Warm Extrusion 121
5.4 Extrusion Defects 121
5.5 Equipment 121
5.5.1 Forming Internal Cavities 122
5.5.2 Direct Extrusion 123
5.5.3 Indirect Extrusion 124
5.5.4 Hydrostatic Extrusion 124
5.5.5 Drives 125
5.5.6 Die Design 125
5.5.6.1 Die Forming (Plastics) 126
5.5.7 Process 126
5.6 Sheet/Film Extrusion 127
5.6.1 Blown Film Extrusion 127
5.7 Over Jacketing 128
5.8 Fiber Drawing of Polymers 130
5.8.1 Spinning Stability 131
5.8.2 Tube Forming 131
5.8.3 Profile Extrusion 131
5.9 Coextrusion 132
5.10 Case Study I 133
5.10.1 Blown Film Extrusion 133
5.10.2 Background Theory on Polymers 134
5.10.3 The Film Blowing Process 134
5.10.4 Advantages 135
5.10.5 Disadvantages 135
5.10.6 Common Problems 135
5.11 Summary 136
References 138
6 Compression for Multiphase Products 140
6.1 Introduction to Compression Molding 140
6.2 Design of Compression Molding 141
6.3 Hydraulic System and Mold 142
6.4 Types of Mold 145
6.5 Mold Design 146
6.6 Control and Operation 148
6.7 Flow Property of Preform 152
6.8 Advantages and Disadvantages of Compression Molding 153
6.9 Transfer Molding 153
6.10 Types of Transfer Molding 154
6.10.1 Pot Type Transfer Molding (True Transfer Molding) 154
6.10.2 Plunger Transfer Molding 155
6.11 Process Characteristics 156
6.12 Test Methods Used Before Molding 157
6.13 Advantages and Disadvantages of Transfer Molding 158
6.14 Comparison of Transfer and Compression Molding 158
6.15 Molding Temperatures of Common Thermosetting Polymers 160
6.16 Molding of Composites 161
References 161
7 Paints and Coating of Multicomponent Product 163
7.1 Introduction 164
7.1.1 Film Formation 165
7.1.1.1 Crosslinking Film Formation 166
7.1.1.2 Evaporation Based Film Formation 167
7.1.1.3 Coalescence Based Film Formation 167
7.1.2 Thermoplastic Polymers 168
7.1.3 Thermoset Polymers 169
7.1.4 Curing Methods 170
7.1.4.1 Physical Curing 170
7.1.4.2 Chemical Curing 170
7.1.4.3 Curing with Heat Carriers 171
7.1.4.4 Curing with Radiation 171
7.1.4.5 Curing by Electrical Methods 172
7.2 Paint Coating 172
7.2.1 Composition of Paints and Film Formation 172
7.2.2 Classification of Paints 173
7.2.3 Paint Coatings 174
7.2.3.1 Primers 174
7.2.3.2 Intermediate Coats 175
7.2.3.3 Finish Coats 175
7.2.3.4 Stripe Coats 175
7.2.3.5 The Paint System 175
7.2.4 Main Generic Types of Paint and Their Properties 176
7.2.5 Prefabrication Primers 176
7.2.5.1 Etch Primers 177
7.2.5.2 Epoxy Primers 177
7.2.5.3 Zinc Epoxy Primers 178
7.2.5.4 Zinc Silicate Primers 178
7.2.6 Application of Paint Coatings 178
7.2.6.1 Brushing 178
7.2.6.2 Roller 178
7.2.6.3 Air Spray 179
7.2.6.4 Airless Spray 179
7.2.7 Conditions of Application 179
7.2.8 Coating Applicator Training and Certification 180
7.3 Coating of Fabrics and Textile or Leather 180
7.4 Spray Coating 183
7.4.1 Overview 183
7.4.2 Airless Atomization 185
7.4.2.1 Advantages 186
7.4.2.2 Disadvantages 186
7.4.3 Flame Spray Coating 186
7.4.4 Spray Transfer Efficiency 187
7.5 Powder Coating 188
7.5.1 Powder Production and Part Preparation 189
7.5.2 Application Techniques 189
7.5.2.1 Electrostatic Spray 190
Powder Coating Guns 191
7.5.2.2 Fluidized Bed 191
7.5.2.3 Tribocharge Spraying 193
7.5.3 Powder Coating Equipment 193
7.5.4 Advantages and Disadvantages 195
7.5.5 Curing of Powder Coatings 196
7.5.6 Developments in Powder Coating 196
7.5.7 Applications 198
7.6 Electrostatic Coating 199
7.6.1 Working 200
7.6.2 Benefits and Applications 200
7.7 Electrodeposition Coating 201
7.7.1 Process Parameters 201
7.7.1.1 Throwing Power 201
7.7.1.2 Maintaining a Steady State 201
7.7.1.3 Rupture Voltage 201
7.7.2 Equipment 202
7.7.2.1 Conveyors 202
7.7.2.2 Metal Preparation 202
7.7.2.3 Tank Enclosures 202
7.7.2.4 Dip Tanks 202
7.7.2.5 Rectifiers 203
7.7.2.6 Counter Electrodes 203
7.7.2.7 Agitation 203
7.7.2.8 Temperature Control 203
7.7.2.9 Ultrafilter 203
7.7.2.10 Paint Filters 203
7.7.2.11 Paint Makeup 203
7.7.2.12 Deionized Water 204
7.7.2.13 Bake or Cure 204
7.7.3 Cathodic Electro Deposition 204
7.7.4 Special Features 205
7.8 Floc Coating 205
7.8.1 Carbon Fiber Based Floc Coatings 205
7.9 Dip Coating 206
7.9.1 Process 206
7.9.2 Dip Coating Techniques 208
7.9.2.1 Self-assembly 208
7.9.2.2 Sol-Gel Technique 209
7.9.2.3 Layer-by-Layer Assembly 209
7.9.3 Advance Developments 210
7.9.4 Advantages 212
7.9.5 Disadvantages 213
7.10 Spin Coating Process 213
7.10.1 The Key Stages in Spin Coating 213
7.10.2 Common Defects and Developments 214
7.10.3 Advantages and Disadvantages 216
7.11 Pinhole Free Thin Coating 216
7.12 Coating Based on the Application 217
7.12.1 Wire and Cable Coating 217
7.12.2 Planar Coating 218
7.12.3 Contour Coating 218
7.12.4 Roll Coating 219
7.13 Conclusion 219
References 219
Applications of Multicomponent Product 233
8 Multilayer Polymer Films 234
8.1 The Significance of Multilayer Polymer Films 234
8.2 Methods of Preparation 235
8.2.1 Layer-by-Layer Assembly 235
8.2.2 Extrusion 236
8.2.3 Co-extrusion [5] 237
8.2.4 Co-injection Stretch Blow Moulding [6] 237
8.2.5 Lamination 238
8.2.5.1 Extrusion Lamination 238
8.2.5.2 Adhesive Lamination [6] 238
8.2.5.3 Heat-Welded Lamination 239
8.2.6 Coating 239
8.2.7 Metallization 240
8.2.8 Thermal Spray Processing of Polymers (“Gun”) 240
8.2.9 Spin Coating 240
8.2.10 Solvent Casting, Painting 241
8.3 Characterization 241
8.3.1 Barrier Properties 241
8.3.1.1 Oxygen Transmission Rate (OTR) 242
8.3.1.2 Water Vapour Permeability 245
8.3.2 Morphological Characterization 246
8.3.3 Mechanical Study 250
8.3.4 X-Ray Diffraction 251
8.3.5 Fourier Transform Infrared Spectrometer 253
8.3.6 Thermal Analysis 254
8.4 Application 256
8.4.1 Food Packaging 256
8.4.2 Agricultural Application 258
8.4.2.1 Mulching 259
8.4.2.2 Multilayer Films for Green Houses 260
8.4.2.3 Controlled Release of Agricultural Chemicals 261
8.4.2.4 Polymeric Windbreaks and Protective Nets 261
8.4.3 Medical Application 261
8.4.4 Optical Devices 261
8.5 Conclusion 262
References 262
9 Hybrid Systems for Multi-layer Fuel and Air Hoses in Automobiles 264
Abstract 264
9.1 Introduction 264
9.2 Multilayer Hybrid Hoses Made Using Rubber 267
9.3 Fluoropolymer Based Hoses 269
9.4 Polyamide Based Multilayer Hybrid Hoses 272
9.5 Fuel Hose for Hydrogen Transport 276
9.6 Hoses Made from Hybrid Yarns 277
9.7 Air Hoses 279
9.8 Standards for Evaluating Multilayer Hoses 281
9.9 Conclusions 281
Acknowledgments 281
References 282
10 Multi Layer Pipes 283
10.1 Introduction 283
10.2 Materials of Multi-layer Pipes 284
10.3 Production of Multi-layer Pipes 285
10.4 Silane Crosslinking Technology 285
10.5 Failure Analysis of Multi-layer Pipes 286
10.6 Lifetime Estimation 288
10.7 Fittings for MLP 289
10.8 Environmental Impact of Multi-layer Pipes 289
10.9 Application of Multi-layer Pipes 291
10.10 Coating for Corrosion Resistance 291
10.10.1 Corrosion Control Methods 294
10.10.2 Erosion Resistance of Fusion Bonded Epoxy Coating 295
10.11 Analysis of Failure of Fusion Bonded Powder Epoxy Internal Coating 300
10.11.1 Differential Scanning Calorimetry (DSC) Analyses 301
10.12 Summary 302
References 302
11 Multilayer (Fuel) Storage Tank 304
11.1 Introduction 304
11.1.1 Need for Multilayer Storage Tanks 305
11.1.2 Overview of Multilayer Assembly 305
11.2 Techniques Involved in Multilayer Coating 306
11.2.1 Spin Coating 307
11.2.2 Dip Coating 308
11.2.3 Spray Coating 309
11.2.4 Vapour Deposition Process 309
11.2.4.1 Physical Vapor Deposition (PVD) 310
11.2.4.2 Chemical Vapor Deposition (CVD) 310
11.2.5 Plasma Spray Coating 311
11.3 Materials and Particles Used for the Construction of LBL Assembled Storage Tanks 311
11.4 Development of Multilayered Films for Fuel Storage Applications 312
11.4.1 Multilayer Assembly for Transport Applications 312
11.4.2 Multilayer Assembly for Hydrogen Barrier Applications 313
11.4.3 Multilayer Assembly for Oxygen Barrier Applications 316
11.4.4 Multilayer Assembly for Hydrogen and Helium Barrier Applications 319
11.4.5 Multilayer Assembly for Methanol Barrier Applications 320
11.4.6 Multilayer Assembly for Gas Turbine Applications 323
11.5 Summary 324
References 325
12 Multilayer Bottles 328
12.1 Why Do We Need Multilayer Polymer Films? 328
12.1.1 Materials Used for Multilayer Bottles 331
12.1.2 Processing of Multilayer Bottles 332
12.1.2.1 Extrusion Multilayer 334
12.1.2.2 Injection Multilayer 336
12.1.2.3 Stretch Blow Molding 337
12.1.2.4 Preform or Bottle Coating 337
12.1.2.5 Bottle Treatment 338
12.1.3 Properties of Multilayered Bottles 339
12.1.3.1 Impact Strength 340
12.1.3.2 Chemical Resistance 340
12.1.3.3 Barrier Properties 340
12.1.3.4 Physical Properties 341
12.1.4 Tests on Multi Layer Plastic Bottles 343
12.1.5 Applications of Multilayered Bottles 349
12.1.6 Conclusion 350
References 350
13 Multiphase Materials for Tire Applications 352
13.1 Introduction 352
13.1.1 Multiphase Materials 352
13.1.2 Need for a Multiphase Material 353
13.2 Fillers Used for the Preparation of Rubber Compounds for Tyre Application 354
13.2.1 Styrene Butadiene Rubber (SBR) 354
13.2.2 Natural Rubber (NR) 354
13.2.3 Carbon Nanomaterials Based Elastomers 355
13.2.3.1 Carbon Black 355
13.2.3.2 Carbon Nanotubes 356
13.2.3.3 Graphite Nanosheets, Graphene and GnO to GnPs 356
13.3 Researches Towards Rubber and Filler Based Composites 357
13.3.1 Silica Based Natural Rubber Composites 357
13.3.1.1 NBR/EPDM Silica Reinforced Composites 358
13.3.2 Clay/NR Rubber Composites 358
13.3.2.1 Clay/EPDM Rubber Nanocomposites 359
13.3.2.2 Clay/NBR Nanocomposites 360
13.3.3 Carbon Nanotubes/Natural Rubber/Carbon Black Composites 361
13.3.4 Polymer/Carbon Black Composites 362
13.3.5 Graphene/Natural Rubber Composites 363
13.3.6 Polypropylene Blended with Scrap Rubber Tyres (SRT) and EPDM 364
13.3.7 Effect of Water Absorption on Mechanical Properties of Multiphase Material Rubber Blend 365
13.3.8 Compatibilization of Rubber Based Blends by Filler Modification 365
13.3.9 Fly Ash Filler with Elastomers 366
13.3.10 Calcium Carbonate/Rubber Composites 367
13.4 Rubbers in Tire Applications 368
13.5 Challenges and Further Research 368
References 369
14 Interfacial Compatibilization of Multilayered Products 371
14.1 Introduction 371
14.2 Thermodynamics of Multilayered Products 372
14.2.1 Prediction of Stability in Multilayers 373
14.3 Compatibilization 373
14.3.1 Interfacial Compatibilization 374
14.3.1.1 Inter Diffusion 375
14.3.1.2 Interfacial Slip 375
14.3.1.3 Interfacial Reaction 376
14.3.2 Method of Compatibilization 376
14.4 Compatibilizers 376
14.5 Morphology—Interfacial Adhesion of Multilayered Polymer Products 377
14.6 Conclusion 382
References 382
15 Multilayer Nanowires and Miscellaneous Multilayer Products 384
15.1 Significance of Polymer Multilayer Products 384
15.2 Polymers as Multilayer Nanowires 385
15.2.1 General Preparation Methods 385
15.2.1.1 Electrospinning 386
15.2.1.2 Stamping or Microtip Writing 386
15.2.1.3 Electrodeposition 387
15.2.1.4 Nanoskiving 387
15.2.1.5 Micromolding 387
15.2.2 Alignment of Nanowires 389
15.2.3 Characterization 389
15.2.3.1 Morphological Characterization 390
15.2.4 Applications 392
15.3 Multilayer Films for Pharmaceutical Applications 394
15.4 Multilayer Polymer Films for Medical Applications 397
15.5 Multilayer Polymer Films for Sensor Applications 400
15.6 Multilayer Polymer Films in Agricultural Field 404
15.7 Multilayer Polymer Films for Miscellanious Applications 405
15.8 Conclusion 409
References 409