Polymers

What are granules?

A small particle of polymer

What are sheets?

Large flat section of polymer in varying thicknesses

What are the stock forms of polymers?

• Granules

• Sheet

• Film

• Rods and extruded forms

• Foam

• Powder

What is foam?

Polymer expanded using heat and gas.

What is powder?

Very fine granules of polymer

How are polymers made?

Fractional distillation of crude oil which is non-renewable

What are synthetic polymers?

They are polymers made from crude oil

How long do polymers take to degrade?

100’s of years

What is the main characteristic of polymers?

They are self-finishing meaning they require no additional finishing processes and can be pigmented during the manufacture.

What are thermoplastics?

A polymer that can be reheated and reshaped repeatedly, meaning it can be recycled

What are thermoset polymers?

A polymer that can only be shaped once. The polymer forms rigid cross-links which cannot be broken. They are permanent in their shape after curing and cannot be remolded or recycled.

What are elastomers?

A polymer that can be deformed at room temperature and will return to the original shape after the force is removed

What are LDPE’s characteristics and what is it used for?

Very tough, has good chemical resistance, weather proof. Low level of rigidity

Used for bottles and food wrap

IT IS A THERMOPLASTIC

What are HDPE’s characteristics and what is it used for?

Weather proof, tough and has good chemical resistance. More rigid than LDPE

Used for chemical drums and containers for household products.

IT IS A THERMOPLASTIC

What are PP’s characteristics and what is it used for?

Good chemical resistance, tough, good fatigue resistance (good for a hinge)

Used for folders and containers

IT IS A THERMOPLASTIC

What are HIPS’s characteristics and what is it used for?

Hard, rigid and tough

Used for Food containers single use drinks cups

IT IS A THERMOPLASTIC

What are ABS’s characteristics and what is it used for?

Tough, hard and impact resistant.

used for automotive parts and protective casings

IT IS A THERMOPLASTIC

What are PMMA’s characteristics and what is it used for?

Tough, hard and has good chemical resistance

Used lighting covers

IT IS A THERMOPLASTIC

What are nylon’s characteristics and what is it used for?

Tough, corrosion resistant, good temperature resistance and has a low coefficient of friction

Used for gears, bearings and electrical insulation.

IT IS A THERMOPLASTIC.

What are uPVC’s characteristics and what is it used for?

Rigid, tough, hard, good weather resistance and good chemical resistance

Used for Window frames and external features such as guttering

IT IS A THERMOPLASTIC

What are flexible PVC’s characteristics and what is it used for?

Tough, flexible, good weathering resistance and good chemical resistance

Used for cable insulation and inflatables

IT IS A THERMOPLASTIC

What are UF’s characteristics and what is it used for?

Hard, heat resistant, good electrical insulator and is brittle

Used for electrical fittings and as an adhesive

IT IS A THERMOSET

What are MF’s characteristics and what is it used for?

Hard, tough, heat resistant, food safe and chemical resistant

Used for buttons and decorative laminates

IT IS A THERMOSET

What are polyester resin’s characteristics and what is it used for?

Rigid, heat resistant, chemical resistant and brittle

Used for castings and composite materials

IT IS A THERMOSET

What are epoxy resin’s characteristics and what is it used for?

Rigid, clear, hard, tough, chemical resistant

Used as an adhesive and in coatings and sealants.

IT IS A THERMOSET.

What are natural rubber’s characteristics and what is it used for?

High tensile strength, low flexibility, hard, tough, electrical insulator and good thermal insulator

Used for tires, seals, and gaskets.

IT IS A ELASTOMER

What are BR’s characteristics and what is it used for?

Tough, excellent fatigue resistance, good thermal resistance and electrical insulator

Used for tires and shoe soles

IT IS A ELASTOMER

What are neoprene’s characteristics and what is it used for?

Good thermal resistance, tough, oil and chemical resistant, weather resistant, abrasion resistant and electrical insulator

Used for wetsuits and cases

IT IS A ELASTOMER

What are silicone’s characteristics and what is it used for?

Good flexibility at all temperatures, poor abrasion resistance, thermal resistant. It is resistant to extreme weather, weather resistant and is an electrical insulator. It is also a good lubricant

Used for flexible molds (ice cube trays), sealants and lubricant

What are the two types of bio-polymer?

• Natural bio-polymer

• Synthetic bio-polymer

What are natural bio-polymers?

Polymers made from natural materials

What are synthetic bio-polymers?

Polymers made from renewable resources but are designed to degrade faster

What are the implications of the use of bio-polymers?

• Can produce methane when decomposed in landfill

• May leave behind toxic residue when decomposed

• Land is used to grow materials to make bio-polymers

• They can not be recycled, may encourage a throwaway culture

• They can be processed the same as any polymer

• Additives can be added to any thermoplastic

How are corn starch polymer’s made and what are they used for?

Made from high-starch vegetables

Used for packaging and disposable cutlery

NATURAL BIO-POLYMER

How is potatopak made and what are they used for?

Made from potato starch

Used for single use food items or packaging

NATURAL BIO-POLYMER

How is biopol (PHB) made and what are they used for?

Made from bacteria grown in cultures. It is an additive to promote degradation

Used in packaging products

NATURAL BIO-POLYMER

How is PLA made and what are they used for?

Made from corn kernels or cane sugar fermented to product lactic acid

Used as filament within 3D printers

IT IS A SYNTHETIC BIO-POLYMER

How is PHA made and what are they used for?

Made from bacteria grown in cultures and is fully compostable

Used in packaging and medicine

NATURAL BIO-POLYMER

How is lactide made and what are they used for?

Made from lactic acid, is fully compostable and water soluble

used for biomedical applications

IT IS A SYNTHETIC BIO-POLYMER

How is Glycolide made and what are they used for?

Made from lactic acid and is fully compostable

Used for food packaging

IT IS A SYNTHETIC BIO-POLYMER

How can bio-polymers degrade?

• light (photodegradable)

• oxygen (oxy-degradable)

• water (hydro-degradable)

Why are lubricants added to polymers?

Reduces the viscosity of the molten polymer. Allows more intricate shapes to be formed

Why are thermal antioxidants added to polymers?

Prevents the polymer from discolouring due to excessive heat

Why are pigments added to polymers?

Gives colour to the final product

Why are antistatics added to polymers?

Reduces static buildup on a polymer’s surface

Why are flame retardants added to polymers?

Reduces the chances of combustion or reduces the spread of fire

Why are plasticisers added to polymers?

Plastics become less hard and brittle at room temperature

Why are fillers added to polymers?

Provides bulk (sawdust and wood flour) to product and reduces costs since less polymer is required

Why are biodegradable plasticisers added to polymers?

Makes plastic more flexible, softer and biodegrades

Why is Bio-batch (Biopol) added to polymers?

It is added to enhance the biodegradability of plastic products, allowing them to break down more easily in the environment.

• Oxy-degradable

• Hydro-degradable

• Photo-degradable

Why are antioxidants added to polymers?

Reduces environmental degradation of polymer

Why are UV light stabilisers added to polymers?

Prevents colour loss and brittleness caused by UV

What is the stock form used in vacuum forming and what are its features?

• thermoplastic sheets

• Moulds are easy to make but can not have sharp edges

• Cost effective for large scale manufacture

• Useful for batch and mass production

What is the stock form used in thermoforming and what are its features?

• Thermoplastic sheets

• Good for fine details

• Slow process

• Used in industrial production

What is the stock form used in calendering and what are its features?

• Thermoplastic pellets

• Makes polymer sheet stock form

• Industrial production method

• Used in continuous production

What is the stock form used in line bending and what are its features?

• Thermoplastic sheets

• Slow and labour intensive

• Suitable for one off or batch production

What is the stock form used in lamination and what are its features?

• Sheets of thermoplastic/ composites

• Expensive and time consuming

What is the stock form used in blow moulding and what are its features?

• Thermoplastic tube

• High initial costs

• Used for continuous production

What is the stock form used in rotational moulding and what are its features?

• Thermoplastic powder or granules

• Hollow components with thick walls

• Large scale mass or batch production

What is the stock form used in extrusion and what are its features?

• Thermoplastic granules

• Industrial production method

• Continuous production

What is the stock form used in compression moulding and what are its features?

• Thermoset polymer

• Large scale batch production

What is the stock form used in injection moulding and what are its features?

• Thermoplastic granules

• Complex 3D shapes can be made

• Fast industrial method

• High initial cost

• Used for large scale manufacture or continuous production

What are over mouldings?

Over mouldings are complex components produced by adding a second layer of polymer over an existing substrate, enhancing strength and functionality while creating a seamless product.

What are acrylic spray paints?

A type of paint that uses acrylic resin as a binder, offering quick drying times and excellent adhesion to various surfaces. They are commonly protective coatings.