Polymer engineering

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Polymer engineering is generally an engineering field that designs, analyses, and modifies polymer materials. Polymer engineering covers aspects of the petrochemical industry, polymerization, structure and characterization of polymers, properties of polymers, compounding and processing of polymers and description of major polymers, structure property relations and applications.

Contents

History

The word “polymer” was introduced by the Swedish chemist J. J. Berzelius. He considered, for example, benzene (C6H6) to be a polymer of ethyne (C2H2). Later, this definition underwent a subtle modification. [1]

The history of human use of polymers has been long since the mid-19th century, when it entered the chemical modification of natural polymers. In 1839, Charles Goodyear found a critical advance in the research of rubber vulcanization, which has turned natural rubber into a practical engineering material. [2] In 1870, J. W. Hyatt uses camphor to plasticize nitrocellulose to make nitrocellulose plastics industrial. 1907 L. Baekeland reported the synthesis of the first thermosetting phenolic resin, which was industrialized in the 1920s, the first synthetic plastic product. [3] In 1920, H. Standinger proposed that polymers are long-chain molecules that are connected by structural units through common covalent bonds. [4] This conclusion laid the foundation for the establishment of modern polymer science. Subsequently, Carothers divided the synthetic polymers into two broad categories, namely a polycondensate obtained by a polycondensation reaction and an addition polymer obtained by a polyaddition reaction. In the 1950s, K. Ziegler and G. Natta discovered a coordination polymerization catalyst and pioneered the era of synthesis of stereoregular polymers. In the decades after the establishment of the concept of macromolecules, the synthesis of high polymers has achieved rapid development, and many important polymers have been industrialized one after another.

Classification

The basic division of polymers into thermoplastics, elastomers and thermosets helps define their areas of application.

Thermoplastics

Thermoplastic refers to a plastic that has heat softening and cooling hardening properties. Most of the plastics we use in our daily lives fall into this category. It becomes soft and even flows when heated, and the cooling becomes hard. This process is reversible and can be repeated. Thermoplastics have relatively low tensile moduli, but also have lower densities and properties such as transparency which make them ideal for consumer products and medical products. They include polyethylene, polypropylene, nylon, acetal resin, polycarbonate and PET, all of which are widely used materials. [5]

Elastomers

An elastomer generally refers to a material that can be restored to its original state after removal of an external force, whereas a material having elasticity is not necessarily an elastomer. The elastomer is only deformed under weak stress, and the stress can be quickly restored to a polymer material close to the original state and size. Elastomers are polymers which have very low moduli and show reversible extension when strained, a valuable property for vibration absorption and damping. They may either be thermoplastic (in which case they are known as Thermoplastic elastomers) or crosslinked, as in most conventional rubber products such as tyres. Typical rubbers used conventionally include natural rubber, nitrile rubber, polychloroprene, polybutadiene, styrene-butadiene and fluorinated rubbers.

Thermosets

A thermosetting resin is used as a main component, and a plastic which forms a product is formed by a cross-linking curing process in combination with various necessary additives. It is liquid in the early stage of the manufacturing or molding process, and it is insoluble and infusible after curing, and it cannot be melted or softened again. Common thermosetting plastics are phenolic plastics, epoxy plastics, aminoplasts, unsaturated polyesters, alkyd plastics, and the like. Thermoset plastics and thermoplastics together constitute the two major components of synthetic plastics. Thermosetting plastics are divided into two types: formaldehyde cross-linking type and other cross-linking type.

Thermosets includes phenolic resins, polyesters and epoxy resins, all of which are used widely in composite materials when reinforced with stiff fibers such as fiberglass and aramids. Since crosslinking stabilises the thermoset polymer matrix of these materials, they have physical properties more similar to traditional engineering materials like steel. However, their very much lower densities compared with metals makes them ideal for lightweight structures. In addition, they suffer less from fatigue, so are ideal for safety-critical parts which are stressed regularly in service.

Materials

Plastic

Plastic is a polymer compound which is polymerized by polyaddition polymerization and polycondensation. It is free to change the composition and shape. It is made up of synthetic resins and fillers, plasticizers, stabilizers, lubricants, colorants and other additives. [6] The main component of plastic is resin. Resin means that the polymer compound has not been added with various additives. The term resin was originally named for the secretion of oil from plants and animals, such as rosin and shellac. Resin accounts for approximately 40% - 100% of the total weight of the plastic. The basic properties of plastics are mainly determined by the nature of the resin, but additives also play an important role. Some plastics are basically made of synthetic resins, with or without additives such as plexiglass, polystyrene, etc. [7]

Fiber

Fiber refers to a continuous or discontinuous filament of one substance. Animals and plant fibers play an important role in maintaining tissue. Fibers are widely used and can be woven into good threads, thread ends and hemp ropes. They can also be woven into fibrous layers when making paper or feel. They are also commonly used to make other materials together with other materials to form composites. Therefore, whether it is natural or synthetic fiber filamentous material. In modern life, the application of fiber is ubiquitous, and there are many high-tech products. [8]

Rubber

Rubber refers to highly elastic polymer materials and reversible shapes. It is elastic at room temperature and can be deformed with a small external force. After removing the external force, it can return to the original state. Rubber is a completely amorphous polymer with a low glass transition temperature and a large molecular weight, often greater than several hundred thousand. Highly elastic polymer compounds can be classified into natural rubber and synthetic rubber. Natural rubber processing extracts gum rubber and grass rubber from plants; synthetic rubber is polymerized by various monomers. Rubber can be used as elastic, insulating, water-impermeable air-resistant materials.

Applications

B-2 Spirit stealth bomber of the U.S. Air Force. USAF B-2 Spirit.jpg
B-2 Spirit stealth bomber of the U.S. Air Force.

Polyethylene

Commonly used polyethylenes can be classified into low density polyethylene (LDPE), high density polyethylene (HDPE), and linear low density polyethylene (LLDPE). Among them, HDPE has better thermal, electrical and mechanical properties, while LDPE and LLDPE have better flexibility, impact properties and film forming properties. LDPE and LLDPE are mainly used for plastic bags, plastic wraps, bottles, pipes and containers; HDPE is widely used in various fields such as film, pipelines and daily necessities because its resistance to many different solvents. [9]

Polypropylene

Polypropylene is widely used in various applications due to its good chemical resistance and weldability. It has lowest density among commodity plastics. It is commonly used in packaging applications, consumer goods, automatic applications and medical applications. Polypropylene sheets are widely used in industrial sector to produce acid and chemical tanks, sheets, pipes, Returnable Transport Packaging (RTP), etc. because of its properties like high tensile strength, resistance to high temperatures and corrosion resistance. [10]

Composites

A time-trial carbon fibre composite bicycle with aerodynamic wheels and aero bars Cyclist itt cyfac(2).jpg
A time-trial carbon fibre composite bicycle with aerodynamic wheels and aero bars

Typical uses of composites are monocoque structures for aerospace and automobiles, as well as more mundane products like fishing rods and bicycles. The stealth bomber was the first all-composite aircraft, but many passenger aircraft like the Airbus and the Boeing 787 use an increasing proportion of composites in their fuselages, such as hydrophobic melamine foam. [11] The quite different physical properties of composites gives designers much greater freedom in shaping parts, which is why composite products often look different from conventional products. On the other hand, some products such as drive shafts, helicopter rotor blades, and propellers look identical to metal precursors owing to the basic functional needs of such components.

Biomedical applications

Biodegradable polymers are widely used materials for many biomedical and pharmaceutical applications. These polymers are considered very promising for controlled drug delivery devices. Biodegradable polymers also offer great potential for wound management, orthopaedic devices, dental applications and tissue engineering. Not like non biodegradable polymers, they won't require a second step of a removal from body. Biodegradable polymers will break down and are absorbed by the body after they served their purpose. Since 1960, polymers prepared from glycolic acid and lactic acid have found a multitude of uses in the medical industry. Polylactates (PLAs) are popular for drug delivery system due to their fast and adjustable degradation rate. [12]

Membrane technologies

Membrane techniques are successfully used in the separation in the liquid and gas systems for years, and the polymeric membranes are used most commonly because they have lower cost to produce and are easy to modify their surface, which make them suitable in different separation processes. Polymers helps in many fields including the application for separation of biological active compounds, proton exchange membranes for fuel cells and membrane contractors for carbon dioxide capture process.

See also

Related Research Articles

<span class="mw-page-title-main">Polyethylene</span> Most common thermoplastic polymer

Polyethylene or polythene (abbreviated PE; IUPAC name polyethene or poly(methylene)) is the most commonly produced plastic. It is a polymer, primarily used for packaging (plastic bags, plastic films, geomembranes and containers including bottles, etc.). As of 2017, over 100 million tonnes of polyethylene resins are being produced annually, accounting for 34% of the total plastics market.

<span class="mw-page-title-main">Thermoplastic</span> Plastic that softens with heat and hardens on cooling

A thermoplastic, or thermosoft plastic, is any plastic polymer material that becomes pliable or moldable at a certain elevated temperature and solidifies upon cooling.

<span class="mw-page-title-main">Thermosetting polymer</span> Polymer obtained by irreversibly hardening (curing) a resin

In materials science, a thermosetting polymer, often called a thermoset, is a polymer that is obtained by irreversibly hardening ("curing") a soft solid or viscous liquid prepolymer (resin). Curing is induced by heat or suitable radiation and may be promoted by high pressure, or mixing with a catalyst. Heat is not necessarily applied externally, but is often generated by the reaction of the resin with a curing agent. Curing results in chemical reactions that create extensive cross-linking between polymer chains to produce an infusible and insoluble polymer network.

<span class="mw-page-title-main">Polymer degradation</span> Alteration in the polymer properties under the influence of environmental factors

Polymer degradation is the reduction in the physical properties of a polymer, such as strength, caused by changes in its chemical composition. Polymers and particularly plastics are subject to degradation at all stages of their product life cycle, including during their initial processing, use, disposal into the environment and recycling. The rate of this degradation varies significantly; biodegradation can take decades, whereas some industrial processes can completely decompose a polymer in hours.

Polymer chemistry is a sub-discipline of chemistry that focuses on the structures of chemicals, chemical synthesis, and chemical and physical properties of polymers and macromolecules. The principles and methods used within polymer chemistry are also applicable through a wide range of other chemistry sub-disciplines like organic chemistry, analytical chemistry, and physical chemistry. Many materials have polymeric structures, from fully inorganic metals and ceramics to DNA and other biological molecules. However, polymer chemistry is typically related to synthetic and organic compositions. Synthetic polymers are ubiquitous in commercial materials and products in everyday use, such as plastics, and rubbers, and are major components of composite materials. Polymer chemistry can also be included in the broader fields of polymer science or even nanotechnology, both of which can be described as encompassing polymer physics and polymer engineering.

<span class="mw-page-title-main">Cross-link</span> Bonds linking one polymer chain to another

In chemistry and biology a cross-link is a bond or a short sequence of bonds that links one polymer chain to another. These links may take the form of covalent bonds or ionic bonds and the polymers can be either synthetic polymers or natural polymers.

<span class="mw-page-title-main">Wood-plastic composite</span> Composite materials made of wood fiber and thermoplastics

Wood-plastic composites (WPCs) are composite materials made of wood fiber/wood flour and thermoplastic(s) such as polythene (PE), polypropylene (PP), polyvinyl chloride (PVC), or polylactic acid (PLA).

<span class="mw-page-title-main">High-density polyethylene</span> Class of polyethylenes

High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a thermoplastic polymer produced from the monomer ethylene. It is sometimes called "alkathene" or "polythene" when used for HDPE pipes. With a high strength-to-density ratio, HDPE is used in the production of plastic bottles, corrosion-resistant piping, geomembranes and plastic lumber. HDPE is commonly recycled, and has the number "2" as its resin identification code.

<span class="mw-page-title-main">Low-density polyethylene</span> Chemical compound

Low-density polyethylene (LDPE) is a thermoplastic made from the monomer ethylene. It was the first grade of polyethylene, produced in 1933 by Imperial Chemical Industries (ICI) using a high pressure process via free radical polymerization. Its manufacture employs the same method today. The EPA estimates 5.7% of LDPE is recycled in the United States. Despite competition from more modern polymers, LDPE continues to be an important plastic grade. In 2013 the worldwide LDPE market reached a volume of about US$33 billion.

A polyolefin is a type of polymer with the general formula (CH2CHR)n where R is an alkyl group. They are usually derived from a small set of simple olefins (alkenes). Dominant in a commercial sense are polyethylene and polypropylene. More specialized polyolefins include polyisobutylene and polymethylpentene. They are all colorless or white oils or solids. Many copolymers are known, such as polybutene, which derives from a mixture of different butene isomers. The name of each polyolefin indicates the olefin from which it is prepared; for example, polyethylene is derived from ethylene, and polymethylpentene is derived from 4-methyl-1-pentene. Polyolefins are not olefins themselves because the double bond of each olefin monomer is opened in order to form the polymer. Monomers having more than one double bond such as butadiene and isoprene yield polymers that contain double bonds (polybutadiene and polyisoprene) and are usually not considered polyolefins. Polyolefins are the foundations of many chemical industries.

<span class="mw-page-title-main">Hot-melt adhesive</span> Glue applied by heating

Hot-melt adhesive (HMA), also known as hot glue, is a form of thermoplastic adhesive that is commonly sold as solid cylindrical sticks of various diameters designed to be applied using a hot glue gun. The gun uses a continuous-duty heating element to melt the plastic glue, which the user pushes through the gun either with a mechanical trigger mechanism on the gun, or with direct finger pressure. The glue squeezed out of the heated nozzle is initially hot enough to burn and even blister skin. The glue is sticky when hot, and solidifies in a few seconds to one minute. Hot-melt adhesives can also be applied by dipping or spraying, and are popular with hobbyists and crafters both for affixing and as an inexpensive alternative to resin casting.

<span class="mw-page-title-main">Polyester</span> Category of polymers, in which the monomers are joined together by ester links

Polyester is a category of polymers that contain the ester functional group in every repeat unit of their main chain. As a specific material, it most commonly refers to a type called polyethylene terephthalate (PET). Polyesters include naturally occurring chemicals, such as in plants and insects, as well as synthetics such as polybutyrate. Natural polyesters and a few synthetic ones are biodegradable, but most synthetic polyesters are not. Synthetic polyesters are used extensively in clothing.

<span class="mw-page-title-main">Biodegradable plastic</span> Plastics that can be decomposed by the action of living organisms

Biodegradable plastics are plastics that can be decomposed by the action of living organisms, usually microbes, into water, carbon dioxide, and biomass. Biodegradable plastics are commonly produced with renewable raw materials, micro-organisms, petrochemicals, or combinations of all three.

<span class="mw-page-title-main">Plastic bottle</span> Bottle constructed of plastic

A plastic bottle is a bottle constructed from high-density or low density plastic. Plastic bottles are typically used to store liquids such as water, soft drinks, motor oil, cooking oil, medicine, shampoo, milk, and ink. The size ranges from very small bottles to large carboys. Consumer blow molded containers often have integral handles or are shaped to facilitate grasping.

<span class="mw-page-title-main">Filler (materials)</span>

Filler materials are particles added to resin or binders that can improve specific properties, make the product cheaper, or a mixture of both. The two largest segments for filler material use is elastomers and plastics. Worldwide, more than 53 million tons of fillers are used every year in application areas such as paper, plastics, rubber, paints, coatings, adhesives, and sealants. As such, fillers, produced by more than 700 companies, rank among the world's major raw materials and are contained in a variety of goods for daily consumer needs. The top filler materials used are ground calcium carbonate (GCC), precipitated calcium carbonate (PCC), kaolin, talc, and carbon black. Filler materials can affect the tensile strength, toughness, heat resistance, color, clarity, etc. A good example of this is the addition of talc to polypropylene. Most of the filler materials used in plastics are mineral or glass based filler materials. Particulates and fibers are the main subgroups of filler materials. Particulates are small particles of filler that are mixed in the matrix where size and aspect ratio are important. Fibers are small circular strands that can be very long and have very high aspect ratios.

Electron-beam processing or electron irradiation (EBI) is a process that involves using electrons, usually of high energy, to treat an object for a variety of purposes. This may take place under elevated temperatures and nitrogen atmosphere. Possible uses for electron irradiation include sterilization, alteration of gemstone colors, and cross-linking of polymers.

<span class="mw-page-title-main">Forensic polymer engineering</span> Study of failure in polymeric products

Forensic polymer engineering is the study of failure in polymeric products. The topic includes the fracture of plastic products, or any other reason why such a product fails in service, or fails to meet its specification. The subject focuses on the material evidence from crime or accident scenes, seeking defects in those materials that might explain why an accident occurred, or the source of a specific material to identify a criminal. Many analytical methods used for polymer identification may be used in investigations, the exact set being determined by the nature of the polymer in question, be it thermoset, thermoplastic, elastomeric or composite in nature.

<span class="mw-page-title-main">Twinwall plastic</span>

Twin-wall plastic, specifically twin-wall polycarbonate, is an extruded multi-wall polymer product created for applications where its strength, thermally insulative properties, and moderate cost are ideal. Polycarbonate, which is most commonly formed through the reaction of Bisphenol A and Carbonyl Chloride, is an extremely versatile material. It is significantly lighter than glass, while managing to be stronger, more flexible, and more impact resistant. Twin-wall polycarbonate is used most commonly for green houses, where it can support itself in a structurally sound configuration, limit the amount of UV light due to its nominal translucence, and can withstand the rigors of daily abuse in an outdoor environment. The stagnant air in the cellular space between sheets provides insulation, and additional cell layers can be extruded to enhance insulative properties at the cost of light transmission.

<span class="mw-page-title-main">Plastic</span> Material of a wide range of synthetic or semi-synthetic organic solids

Plastics are a wide range of synthetic or semi-synthetic materials that use polymers as a main ingredient. Their plasticity makes it possible for plastics to be moulded, extruded or pressed into solid objects of various shapes. This adaptability, plus a wide range of other properties, such as being lightweight, durable, flexible, and inexpensive to produce, has led to its widespread use. Plastics typically are made through human industrial systems. Most modern plastics are derived from fossil fuel-based chemicals like natural gas or petroleum; however, recent industrial methods use variants made from renewable materials, such as corn or cotton derivatives.

Biodegradable additives are additives that enhance the biodegradation of polymers by allowing microorganisms to utilize the carbon within the polymer chain as a source of energy. Biodegradable additives attract microorganisms to the polymer through quorum sensing after biofilm creation on the plastic product. Additives are generally in masterbatch formation that use carrier resins such as polyethylene (PE), polypropylene (PP), polystyrene (PS) or polyethylene terephthalate (PET).

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