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2 Plastics Materials Properties and Applications Second Edition A.W. BIRLEY R.J.HEATH Institute of Polymer Technology and Materials Engineering University of Technology Loughborough, UK M.J. SCOTT Lowe & Fletcher Ltd Telford, UK BLACKIE ACADEMIC & PROFESSIONAL An Imprint of Chapman & Hall London Glasgow New York Tokyo Melbourne Madras

3 Published by B1ackie Academic & Professional, an imprint of Chapman & Hall, Wester Cleddens Road, Bishopbriggs, Glasgow G64 2NZ, UK Chapman & Hall, 2-6 Boundary Row, London SE1 8HN, UK B1ackie Academic & Professional, Wester Cleddens Road, Bishopbriggs, Glasgow G64 2NZ, UK Chapman & Hall GmbH, Pappeiallee 3,69469 Weinheim, Germany Chapman & Hall USA, One Penn Plaza, 41st Floor, New York, NY10119, USA Chapman & Hall Japan, ITP-Japan, Kyowa Building, 3F, Hirakawacho, Chiyoda-ku, Tokyo 102, Japan DA Book (Aust.) Pty Ltd, 648 Whitehorse Road, Mitcham 3132, Victoria, Australia Chapman & Hall India, R. Seshadri, 32 Second Main Road, CIT East, Madras , India First edition 1982 Second edition 1988 Reprinted B1ackie & Son Ltd Typeset by Thomson Press (India) Ltd, New Delhi ISBN ISBN (ebook) DOl / Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publication may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permission in writing of the publishers, or in the case of reprographic reproduction only in accordance with the terms of the licences issued by the Copyright Licensing Agency in the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK. Enquiries concerning reproduction outside the terms stated here should be sent to the publishers at the Glasgow address printed on this page. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made. A Catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data available

4 Preface Plastics are part of everyday life and contribute immensely to the benefit of humanity. When failures occur, they are due in part either to inferior properties (resulting from poor design or badly controlled processing), or to an incomplete understanding of the properties and applications of plastics materials. Since publication of the first edition, the plastics industry has increasingly adopted advanced business procedures and automation (such as closed loop control and robotics), to combat the effects of recession, and has moved increasingly towards methods based on sound scientific and technological principles. Plastics have increasingly been used in applications once dominated by the use of metals and ceramics. For instance, in the automotive industry, the modern car now contains a much higher proportion of polymers, including commodity plastics and more specialized materials. In addition, compact discs are being made from new injection-moulding grades of polycarbonate, which meet the requirements of a demanding process. This second edition has been thoroughly revised and extended to include new materials, technologies and design concepts. Chapters on thermoplastics reflect the development of polymer blends and alloys, whilst the chapters devoted to thermosets have been reorganized to accommodate the renaissance in the applications of phenolics and to cover the growing importance of polyurethanes. The related twocomponent process technologies are now included; having undergone major developments in the last decade, they have become important shaping processes. We hope that readers, whether new to or experienced in plastics technology, will find in this book something that will extend their knowledge and increase their understanding of the field. AWB RJH MS

5 Contents 1 Introduction 1.1 Background 1.2 Structure and properties of plastics Mechanical properties Thermal properties Electrical properties Optical properties Melt properties Chemical properties 1.3 Additives 1.4 Processing of plastics Thermoplastics processing Foams Shaping of cross-linking plastics 1.5 Practical methods of processing Thermoplastics processing Processing methods for cross-linking plastics 1.6 Interactions between shaping process and plastics materials Further reading 2 Fundamentals of design 2.1 Engineering design Fracture mechanics applied to plastics 2.2 Design limitations imposed by processing method 2.3 Product design Thermoplastics Thermosetting plastics Foams and reinforced plastics Tolerance and dimensional control of products 2.4 Importance of economics of processing in design Further reading 3 Styrene plastics 3.1 Polystyrene 3.2 High impact polystyrene 3.3 Styrene copolymers 3.4 ABS plastics 3.5 Polystyrene-poly(phenylene oxide) blends 4 Other amorphous thermoplastics 4.1 Poly(methyl methacrylate) 4.2 Cellulose plastics Regenerated cellulose Cellulose esters Cellulose ethers 4.3 Polycarbonates 1 1 I

6 viii CONTENTS 5 Propylene plastics 5.1 Homopolymer and impact-modified grades 5.2 Filled polypropylene 5.3 Foamed polypropylene 5.4 Miscellaneous applications of propylene polymers 6 Other polyolefin plastics 6.1 Polyethylene High-density polyethylene Low-density polyethylene Linear low-density polyethylene Very low-density polyethylene Blends of ethylene polymers 6.2 Ethylene copolymers 6.3 Polybut-1-ene 6.4 Poly-4-methylpent-1-ene 7 Other crystalline thermoplastics 7.1 Polyamides General-purpose polyamides Modified polyamides Aromatic polyamides and polyimides 7.2 Thermoplastic polyesters Homo-polyesters Blends of polyesters 7.3 Polyacetals 8 Vinyl chloride plastics 8.1 Un plasticized poly(vinyl chloride) 8.2 Plasticized poly(vinyl chloride) 8.3 Vinyl chloride copolymers 8.4 Blends of poly(vinyl chloride) 8.5 Vinylidene chloride polymers and copolymers 9 Speciality therntoplastics 9.1 Fluoroplastics Poly(tetrafluoroethylene) Poly(vinylidene fluoride) Other fluoropolymers 9.2 Polysulphones 9.3 Poly(phenylene sulphide) 10 Cross-linked plastics 10.1 Introduction 10.2 Phenol-formaldehyde plastics Novolak PF resins Resol PF resins 10.3 Urea-formaldehyde plastics 10.4 Melamine-formaldehyde plastics 10.5 Unsaturated polyester resins Structure and properties Glass fibre-reinforced polyesters 10.6 Epoxide resins 11 Polyurethane plastics 11.1 Introduction 11.2 Molecular structure-property relationships

7 CONTENTS Typical reactions Monomeric components 11.3 Properties and applications of polyurethanes Flexible polyurethane foams Rigid polyurethane and polyisocyanurate foams Reaction injection moulded polyurethane products Elastomeric and resinous thermosetting polyurethanes Thermoplastic polyurethanes Polyurethanes as surface coatings, adhesives and sealants Further reading ix Index 193