Thermoforming -  Muralisrinivasan Natamai Subramanian

Thermoforming (eBook)

Processing and Technology
eBook Download: EPUB
2024 | 1. Auflage
352 Seiten
Wiley (Verlag)
978-1-119-55590-2 (ISBN)
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This book is a comprehensive reference manual that contains essential information on thermoforming processing and technology.

The field of thermoforming is experiencing rapid development driven by commercial factors; millions of tons of polymers are manufactured for use in various applications, both as commodity and specialty polymers. Building on the previous edition published about ten years ago, this edition includes new, as well as, fully revised chapters and updated information on materials and processes. The book is designed to provide practitioners with essential information on processing and technology in a concise manner. The book caters to both engineers and experts by providing introductory aspects, background information, and an overview of thermoforming processing and technology. The troubleshooting section includes flowcharts to assist in correcting thermoforming processes.

>em>Thermoforming: Processing and Technology offers a complete account of thermoplastics, covering properties and forming, with chapters providing perspective on the technologies involved. Readers will find it:

  • serves as a handy knowledge source for professionals who occasionally work on thermoforming projects or need to refresh their knowledge;
  • offers a troubleshooting guide that can help to identify and solve challenges that may arise in thermoforming processes;
  • provides insights into process optimization, helping businesses improve efficiency, reduce waste, and enhance the quality of thermoformed products;
  • acts as a course book to inform students about the thermoforming process.

Audience

The book will be of interest to mechanical, materials engineers, and process engineers who are involved in designing and optimizing thermoforming processes; professionals in the manufacturing and production industries who use thermoforming as a manufacturing method, such as in the production of plastic packaging, automotive components, and consumer goods; scientists, researchers, and students in plastics/polymer engineering and technology, materials science, polymer technology; professionals responsible for ensuring product quality and compliance with industry standards.


This book is a comprehensive reference manual that contains essential information on thermoforming processing and technology. The field of thermoforming is experiencing rapid development driven by commercial factors; millions of tons of polymers are manufactured for use in various applications, both as commodity and specialty polymers. Building on the previous edition published about ten years ago, this edition includes new, as well as, fully revised chapters and updated information on materials and processes. The book is designed to provide practitioners with essential information on processing and technology in a concise manner. The book caters to both engineers and experts by providing introductory aspects, background information, and an overview of thermoforming processing and technology. The troubleshooting section includes flowcharts to assist in correcting thermoforming processes. >em>Thermoforming: Processing and Technology offers a complete account of thermoplastics, covering properties and forming, with chapters providing perspective on the technologies involved. Readers will find it: <ul> <li>serves as a handy knowledge source for professionals who occasionally work on thermoforming projects or need to refresh their knowledge;</li> <li>offers a troubleshooting guide that can help to identify and solve challenges that may arise in thermoforming processes;</li> <li>provides insights into process optimization, helping businesses improve efficiency, reduce waste, and enhance the quality of thermoformed products;</li> <li>acts as a course book to inform students about the thermoforming process.</li> </ul> Audience The book will be of interest to mechanical, materials engineers, and process engineers who are involved in designing and optimizing thermoforming processes; professionals in the manufacturing and production industries who use thermoforming as a manufacturing method, such as in the production of plastic packaging, automotive components, and consumer goods; scientists, researchers, and students in plastics/polymer engineering and technology, materials science, polymer technology; professionals responsible for ensuring product quality and compliance with industry standards.

2
Polymers


2.1 Introduction


Polymers have experienced steady market growth and are widely acknowledged as a significant category of materials. These materials possess characteristics such as affordability, ease of manipulation, and versatility, rendering them suitable for a diverse array of applications. These applications encompass a wide range of household items, packaging materials, advanced fibers, medical devices, and wearable electronics. The application of polymers has greatly enhanced our standard of living and sparked revolutionary progress in various sectors [1, 2].

The prevalence of synthetic polymers can be attributed to the fact that 90% of these polymers are derived from finite fossil feedstock. The incorporation of these materials into diverse products is driven by their exceptional stability, processability, versatile mechanical properties, and durability. Although the terms plastics and polymers are often used interchangeably, it is crucial to acknowledge that there is a subtle distinction between them [3, 4].

Polymer engineering encompasses the technological processes used for the complete synthesis of meticulously regulated macromolecules. The objective of polymer engineering is to attain mastery over the physical characteristics of macromolecules, encompassing factors such as molecular weight, molecular weight distribution, end functionality, tacticity, stereochemistry, block sequence, and block topology. Polymers find applications in a wide range of consumer products such as carpets, furniture, glues, and clothing. In addition, they play a crucial role in advanced engineering, particularly in the development of materials used in the aerospace industry. Therefore, the utilization of polymers and their constituent monomers is important in our daily lives [5].

2.2 Physics and Chemistry of Polymers


The study of polymer materials is a complex and intriguing subject in physics and chemistry. The structure of a polymer is determined by the number and type of repeating units it contains. Polymer science investigates the characteristics, composition, and behavior of these substances at the atomic, molecular, and macroscopic levels. This multidisciplinary field combines concepts from biology, engineering, chemistry, and physics to understand and manipulate material properties for specific purposes. Many polymeric materials exhibit emergent properties, which are unique characteristics arising from the interaction of their constituent monomers.

One particularly fascinating aspect of chemistry and polymer science is the ability to transition materials between different phases, particularly in relation to the monomers. These transitions allow the manipulation of materials for real-world applications. This process is not only scientifically intriguing, but also essential for the development of new and innovative materials with a wide range of uses in modern technology and everyday life. This is particularly true for monomers that form polymers [6, 7].

Polymer molecules consist of a sequence of monomers that are joined by chemical bonds. The orientations of these bonds between successive monomers are correlated with those of adjacent monomers and crossing energy barriers is necessary for a bond to change its orientation. The arrangement of monomers within a polymer significantly affects its characteristics. Describing the behavior of materials at different length scales, from atomic interactions to macroscopic properties, is challenging. The development of polymer materials with specific properties is crucial for numerous technological advancements.

Even small variations in the arrangement of monomers can lead to significant differences in the material behavior. Polymers are highly versatile due to their flexible design, structure, and chemical composition, allowing them to exhibit a wide range of properties that can be tailored to meet specific requirements [8].

2.3 Natural Polymers


Natural polymers, which are associated with biopolymers, are formed through metabolic processes in living organisms [9]. These polymers consist of monomeric units that are linked by covalent bonds. Examples of natural polymers include proteins such as collagen and silk fibroin as well as polysaccharides such as chitosan, alginate, hyaluronic acid, and cellulose [10]. These polymers play important roles in nature, including the preservation and transmission of genetic information and the storage of cellular energy. One of their key advantages is their ability to biodegrade, with the released CO2 rapidly absorbed by agricultural crops and soil. Among polysaccharide biopolymers, cellulose is particularly abundant and is present in approximately 33% of all plant components [11, 12]. Other notable natural polymers include chitin/chitosan, starch, and lignin. Chitosan, alginate, cellulose, lignocellulose, starch, and PVA are among the most promising and frequently studied natural polymers, either as standalone materials or in combination with other advanced materials [13].

2.4 Synthetic Polymers


Synthetic polymers belong to a distinct class of polymers derived from crude oil, petrochemicals, natural gas, or biomass. These polymers possess a wide range of desirable characteristics such as low density, high durability, and resistance to deterioration. In addition to their advantages in terms of weight and cost, polymer products offer enhanced durability that can help prevent damage during transportation. Furthermore, many polymers exhibit corrosion resistance, making them well suited for use in harsh environments, such as chemical manufacturing facilities [14].

Polymerization, which involves chemically bonding monomers to form long chains, is utilized to produce synthetic polymers, which are subsequently used in various manufacturing processes. Synthetic polymeric networks consist of repeatable inert units and are generally superior to natural polymers in terms of mechanical properties and immunogenic responses [15].

Synthetic polymers offer tailored structures and properties through the appropriate design of their functional groups. These advantages ensure predictable, reproducible, and adjustable properties, which can vary according to specific applications. For example, the degradation rate of synthetic polymers can be altered by manipulating their chemical compositions, crystallinities, and molecular weights.

The ability to process and shape polymers enables the efficient mass production of a diverse range of items. Techniques, such as injection molding, extrusion, blow molding, and thermoforming, facilitate the creation of complex designs and ensure reliable quality. The lightweight nature of plastic products contributes to reducing shipping expenses and energy consumption. Moreover, manufacturing products from plastics is often more cost-effective than manufacturing conventional materials [16].

2.5 Polymerization Methods


During the polymerization process, monomers undergo chemical bonding to form extensive chains or networks, resulting in the development of unique polymer properties. This chemical reaction, known as a polymerization reaction, leads to the formation of high-molecular-weight molecules from the monomers [17]. The structural features of polymers, such as linear, branched, or network configurations, are determined by the arrangement of monomers and the types of chemical bonds that connect them. The ability to manipulate the structure and composition of polymers is crucial in various industries and applications. Two primary approaches are utilized in the production of polymers: addition and condensation polymerization. Both mechanisms can be used in the polymerization of the same monomer or different monomers can be used to create the same polymer through both approaches, provided that suitable functional groups are available for each individual polymerization. Addition and condensation polymerizations are both essential in the creation of diverse polymers, fibers, rubbers, and other materials that have extensive applications in everyday life and industry. The selection of specific monomers and the desired characteristics of the final polymer product determine the appropriate polymerization method [18, 19].

2.5.1 Addition Polymerization


In this process, the reaction between monomers containing double or triple bonds leads to the formation of polymer chains. This involves the breaking of the double or triple bonds and the subsequent connection of the monomers without the production of any byproducts. The double bonds of the monomers react without releasing any molecules. These reactions occur via the addition of monomer molecules via unsaturated (double) bonds [20].

The initiation of the reaction can be achieved using chemical molecules, such as azo compounds or peroxides, or through physical sources, such as heat or electromagnetic radiation. These initiators create radicals, anions, or cations in the monomer. Depending on the type of initiation, addition polymerization can be classified as radical, anionic, cationic, or coordination polymerization. All addition polymerizations involve three stages: initiation, propagation, and termination [18, 21].

In the case of addition polymerization, a reactive center such as a radical, an anion, or a cation must first be created on a molecule that contains a double bond. New monomer molecules are then successively added to this active molecule, creating a new active center for further addition. This process continues...

Erscheint lt. Verlag 21.6.2024
Sprache englisch
Themenwelt Naturwissenschaften Chemie
ISBN-10 1-119-55590-6 / 1119555906
ISBN-13 978-1-119-55590-2 / 9781119555902
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