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A).SUSPENSION POLYMERISATION:
It is also known as Pearl polymerization (or) Bead polymerization (or) Granular polymerization.
It is polymerization process that uses mechanical agitations to mixture of monomers in liquid state such
as water. in this process, the monomers are dispersed as a relatively large droplets (0.1-1 mm.) in liquids.
it is kept in suspension by mechanical agitations and then a catalyst is added for initiation of
polymerization process. The viscosity of dispersed drops increased and they become sticky. At this stage
suspension is stabilized by adding stabilizer agents (Al(OH)3, Magnesium silicate) otherwise the droplets
agglomerate together and dip away, thus breaking the suspension. The polymerization is continued until
each droplet gets converted in to 100% and the polymers are obtained as pearls (or) spherical beads. The
product is washed to remove stabilizer on surface and dried before use.
Example: PS,PVC.
Advantages:
1) The purity of polymer is higher in this method in comparison to Emulsion polymerization.
2) Viscosity is low throughout and temperature can be easily controlled.
Disadvantage:
1) It is highly sensitive for agitation and is difficult to control the size of the particles.
B) EMULSION POLYMERIZATION:
It is a type of radical polymerization, that starts with an emulsion water monomer and surfactant.
The most common type of emulsion polymerization is an Oil-in-water emulsion.
In this method the monomer is dispersed in a water phase as fine droplets (10-5-10-6) which are
stabilized by adding surfactants (soap/detergent). The surfactants will form micelles when their
concentration exceeds critical micelle concentration (CMC) that are dispersed throughout the solution.
The addition of initiator leads to activation of reaction in the micelles. Due to the formation of polymers
these micelles increase in size. To continue the reaction, monomer diffuses from its droplets to micelle.
Hence high molecular weight polymers can be obtained. The polymers made by this method can be used
in the emulsion form itself for applications like surface coating (or) textile finishes.
Examples: PS,PVC
Advantages:
Disadvantages:
1) It is economically costly.
2) It can’t be used for condensation, ionic, Ziegler- natta polymerization process.
PHYSICAL PROPERTIES:
2.MOLECULAR WEIGHT: A non-polymeric simple compound possess a fixed molecular weight. Eg:
Na2CO3 possess 106 as molecular weight. When polymerization takes place, the polymer molecule have
different number of monomeric units hence different molecular weights. As a result the molecular weight
of polymer should be expressed as average molecular weight.
Ex:
3.SOLUBILITY: When a polymer is dissolved in a suitable solvent, the polymer absorbs water and
swells in size. Slowly polymer goes into the solution a viscous polymer solution which is heterogeneous.
Where as a non-polymer like NaCl when added to water, ionizes and form homogenous solution.
4.EFFECT OF HEAT ON POLYMER: At room temp. all polymers are solids existing in rubbery state.
As the temp. increases the polymer melts and this is called the melting point of polymer (T f). As the
temp. further increases to boiling (Tb) the polymer decomposes to monomers which are in vapour phase.
When the temp. is lowered below zero degree where the polymer becomes hard, brittle and glassy and
the polymer behaves like glass. this temp. is called glass transition temp (Tg). Tg of rubber is -73 degrees.
MECHANICAL PROPERTIES:
1.TOUGHNESS: The impact strength is measured as toughness. Below glass transition temperature (Tg)
the polymers break with a brittle fracture and they become tougher when the temp. proceeds from room
temp. to Tg.
2. STRENGTH: The strength of a polymer depend on length of polymer chain, branching chain. The
strength of a polymer increases with increase in molecular weight. The strength of a polymer is
determined by stress-strain test. Typical stress strain curves for different types of polymer is shown
below.
3.ELASTICITY: Elasticity is the property of recovering original shape after the removal of deforming
stress. Natural rubber possess high elasticity due to the coiled helix structure of poly-isoprene.
PLASTICS
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Depending on its ultimate properties, polymers can be classified into three types.
Definition: Plastics are high molecular weight organic polymers which show the property of plasticity
and can be moulded into desired shape by applying heat and pressure in presence of catalyst.
Advantages:
THERMOPLASTICS: These are linear and long chain polymers, which soften on heating and harden
when cooled. Their hardness is a temporary property. The intermolecular forces in these polymers are
intermediate between those of elastomers and fibers. This polymers can be readily recycled.
COMPOUNDING OF PLASTICS:
Polymer in its pure form is called Virgin polymer. Virgin polymer can’t be moulded with out adding
other ingredients. So “ The process of addition of other chemical ingredients to improve the properties of
polymer and make them convenient for moulding is known as Compounding of plastics”. Compounding
ingredients are,
1.Binders: Binder is the major ingredient present in a plastic material. Binder hold the other ingredients
together. There are two kinds of binders namely Thermoplastics and Thermosetting plastics.
Due to the presence of long and linear structure, thermoplastic resins becomes soft and can be
moulded into desired shape on heating, and again become rigid on cooling.
Due to the presence of cross linked three dimensional structure, thermosetting resins become
permanently hard and rigid on heating excess heat chars the material.
2. Fillers: Fillers are cheap organic or in-organic compounds which are added to improve certain
properties like hardness, tensile strength.
3. Plasticizers: Plasticizers are inert high molecular weight organic compounds which are freely miscible
with plastic material. As plasticizers reduce the viscosity of the plastic, they increase the plasticity.
4.Colourants: These are in-organic or organic pigments used to improve the colour of a plastic article.
5.Catalysts: These are used only in the case of thermosetting resins. The function of these catalyst is to
convert fusible resin into cross-linked infusible resin during moulding operation.
6.Stabilizers: These are added to the plastics to improve thermal stability during moulding.
7.Fire retards: These are used as additives to prevent plastics from burnings.
8.Anti-oxidant: These are added to plastics during moulding to prevent oxidation of resin and gives long
life to the plastic material.
Ex: Di-phenyl amines.
FABRICATION OF PLASTICS:
Plastic fabrication is the design or manufacture through one of a no of methods. There are different
fabrication techniques.
1.Extrusion moulding: Using this process, it is possible to produce a wide range of different forms of
plastics, such as tubes, sheets and films. Plastic pellets are placed in a feed hopper which feed into the
system.
A turning screw pushes the plastic into the barrel, where heaters increase the temp. and a melted
polymer is obtained. The melted plastic is forced through a shaping die depending on the particular shape
of this element. A continuous shape is formed and pulled out of the extrusion machine.
2.Injuction moulding: Plastic pellets flow due to gravity from the feed hopper into a turning screw. It is
converted into a melted plastic by the action of heaters situated along the barrel.
`The screw moves the molten plastic forward forcing the plastic through a gate into the cooled mould.
The mould is opened once the plastic has solidified and the piece is pushed from the mould by automatic
ejector pins. After we get the manufactured piece, the mould is closed and clamped and the process
begins again.
After the gate, the molten charge is quickly transferred to a press where it is moulded while still
hot. The part is removed after sufficient cooling.
4.Blown film moulding: Plastic glocery bags, bottles and similar items are made using this processing as
in compression processing, plastic pellets are melted and the plastic is forced through a gate into the blow
pin camera.
The plastic substance is expanded and cooled by being made to flow around a massive air bubble.
After a few seconds, the mould is opened and the manufactured product is ready.
POLYETHYLENE or PE:
Polyethylene is most commonly used polymer, produced by the polymerization of ethylene in
presence of a catalyst. By using initiator (benzoyl peroxide) at 80-125 0C low density polythene
(LDPE) with density of 0.92g/ccis produced, while by using an ionic catalyst like tri ethyl
aluminium,, high- density polythene (HDPE) with density 0.965g/cc is obtained.
Preparation:
Properties:
1. Polyethylene is a rigid, waxy, white, translucent, non polar solid material with good electrical
insulation property. It is a soft flexible polymer.
2. It exhibits chemical resistance to strong acids, alkali and salt solutions at room temperature.
Engineering applications:
PE is used for making high frequency insulator parts, bottle caps, packing materials, tubes, coated
wires, tank linings in chemical plants and domestic appliances.
It is a thermoplastic polymer and is obtained by the free radical addition polymerization of vinyl
chloride in the presence of benzyl peroxide or hydrogen peroxide. Vinyl chloride is obtained by treating
acetylene with HCl at 60-800C in the presence of metal oxide catalyst.
Properties:
BAKELITE:
It is prepared by condensing phenol with formaldehyde in presence of acidic/alkaline
catalyst. The initial reaction results in the formation of non polymeric mono, di and tri
methylol phenols depending on the reactant ratio. These compounds in the first stage react
to form a linear polymer, Novolac. Novolac in the second stage undergoes further reaction
with these linear polymers to form cross linking and bakelite plastic resin is produced.
All these stages in a step wise manner are shown in the reaction below, ultimately
giving the cross linking polymer, bakelite.
Properties:
1. Bakelite is usually dark colored substance.
2. It is hard, rigid and strong material with respect to heat and pressure.
3. It has good chemical resistance and good electrical insulator.
Engineering applications:
The phenol-formaldehyde resins are extensively used
1. for making electric insulator parts like switches, plugs, switch-boards, heater handles, etc.
2. for making moulded articles like telephone accessories, cabinets for radio and television.
3. for impregnating fabrics, wood and paper.
4. In paints and varnishes.
5. As hydroxyl group exchanger resins in water softening
6. For making bearings, used in propeller shafts for paper industry and rolling mills.
Ethylene vinyl acetate - Freezer door strips, vacuum lean hoses, handle-grips
Polyamide - Adaptors
Polycarbonate - Telephones
The e-waste recycling process is highly labor intensive and goes through several steps. Below is
the step-by-step process of how e-waste is recycled,
1.Picking Shed:
When the e-waste items arrive at the recycling plants, the first step involves sorting all the
items manually. Batteries are removed for quality check.
2.Disassembly:
After sorting by hand, the second step involves a serious labor intensive process of manual
dismantling. The e-waste items are taken apart to retrieve all the parts and then categorized into
core materials and components. The dismantled items are then separated into various categories
into parts that can be re-used or still continue the recycling processes.
Here, items that cannot be dismantled efficiently are shredded together with the other
dismantled parts to pieces less than 2 inches in diameter. It is done in preparation for further
categorization of the finer e-waste pieces.
The finer e-waste particles are then evenly spread out through an automated shaking process
on a conveyor belt. The well spread out e-waste pieces are then broken down further. At this stage,
any dust is extracted and discarded in a way that does not degrade the environmentally.
5.Over-band Magnet:
At this step, over-band magnet is used to remove all the magnetic materials including steel and
iron from the e-waste debris.
The sixth step is the separation of metals and non-metallic components. Copper, aluminum,
and brass are separated from the debris to only leave behind non-metallic materials. The metals are
either sold as raw materials or re-used for fresh manufacture.
7.Water Separation:
As the last step, plastic content is separated from glass by use of water. One separated, all the
materials retrieved can then be resold as raw materials for re-use. The products sold include
plastic, glass, copper, iron, steel, shredded circuit boards, and valuable metal mix.
ELASTOMERS:
Elastomers can be defined as the long chain polymer which undergo elongation under stress
and regain its original shape when stress is released.
Elastomers are classified into two types: 1. Natural rubber. 2. Synthetic rubber.
1. Natural rubber:
Vulcanization of rubber:
Vulcanization is compounding of rubber with sulphur.
Vulcanization is done by heating rubber with sulphur at 140 C in CO2
atmosphere.
Sulphur adds to the double bonds present in rubber to provide cross links between the polymer
chains.
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2 to 4% Sulphur addition gives soft elastic rubber. When sulphur content is more than 30%, we
get hard rubber called 'Ebonite'
1. Vulcanized rubber has very little electrical and thermal conductivity. Hence, it is
mainly used for electrical insulation purposes.
2. It has high elasticity and tensile strength.
3. Corrosive chemicals and oils do not affect it.
4. It is also not affected by atmosphere.
SYNTHETIC RUBBERS:
1. Buna-S (Styrene Butadiene Rubber: SBR): Buna is a copolymer of 75% butadiene (CH 2=CH–
CH=CH2) and 25% of styrene (C 6H5CH=CH2). The polymerisation is carried out at 50°C in the
presence of peroxide catalyst.
Properties
1) It is high load bearing capacity.
2) It is sensitive to Oil, waste water and Ozone..
3) It is a good electrical insulator.
Properties
1. Thiokol is resistant to swelling, oils, solvents and fuels.
2. Thiokol is inert to fuels, lubricating oils, gasoline and kerosene.
3. It can’t be vulcanized and hence does not form a hard rubber.
Uses
1. It is used for coating fabrics, for making ballons and life jackets.
2. It is used for making gaskets, diaphragms and seals in contact with solvent and for printing
rolls.
Properties:
1. It has high strength, good resistance to ozone and weather proof.
2. It is highly resistant to oxidation, because of the saturated character. It have good
resistance to many organic solvents.
Engineering Applications
1. It used for surface coatings, manufacture of foams & spandex fibres.
2. PU flexible foams are employed as furniture material, insulation & crash pads.
3. It is used for insulating wires, the PU coated wires can be soldered directly.
COMPOSITE MATERIALS:
Various metals metals, high polymers, ceramics etc have their own different
characteristics. They have different limitations. So these are not used at all places. In order to make
them use in engineering and other applications, scientists have developed a new class of materials
called composites.
FIBRE REINFORCED PLASTICS (FRP)
Fibre reinforced plastics are produced by reinforcing a plastic matrix with a high strength
fibre materials such as glass, graphite, alumina, carbon, boron, beryllium. Natural fibres such as
sisal, asbestos are also used for reinforcement.
BIO-DEGRADABLE POLYMERS:
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Polymers either biopolymers or synthetic polymers are reasonably stable, but they undergo
degradation when exposed to moisture , heat, oxygen, Ozone and micro-organisms etc. these
agents lead to the breakdown of chemical structure of polymer, resulting in change in the
properties of polymer.
Biodegradation can be measured in activity aerobic microbes the amount of O 2 they
consume or the amount of CO2 they produced.
Biodegradable plastics are two types. Hydro-biodegradable plastic (HBP), which undergo
chemical degradation by hydrolysis. And Oxo-biodegradable plastic (OBP), which undergo
chemical degradation by oxidation.
Some natural biodegradable polymers are Rubber, Cellulose etc.
The synthetic biodegradable polymers are poly caprolactone and poly vinyl acetate.
Properties:
1. Bio-degradable polymers should be non-toxic.
2. Capable of controlled rates of degradation.
Uses:
1. Used in dental devices and Orthopedic fixation devices.
2. Used in drug delivery system.
CONDUCTING POLYMERS:
Most of the polymeric materials are poor conductors of electricity. Even some are insulators,
because free electrons are not available.
Polymeric materials have been synthesized and they possess electrical conductivity more then
to standard polymer and less then to metals like copper. Such polymers are called conducting
polymers. Ex: poly acetylene, poly pyrrole, poly aniline, poly naphthalene, poly quinoline etc
Conducting polymers are of two types.
A).Intrinsically conducting polymers: polymers in which the intensive conjugation is responsible
for electrical conductance are known as Intrinsically conducting polymers. These are further
divided in to two types.
1).Conjugated conducting polymers: In conjugated polymers, the electron orbitals or non-bonding
orbital’s or both are overlapping over the entire backbone of polymer resulting in the formation of
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valence bonds as well as conduction bands with some significant band gap throughout the polymer
molecule.
In an electric field conjugated electrons of the polymer get excited with sufficient energy to
the gap and reach into the higher levels of the conduction band. During this excitation, the charge
transfers through the entire polymeric molecule.
2).Doped conducting polymers: The conductivities can be enhanced by doping either +ve or -ve
charge on polymer backbone with charge transfer agents. Doped conducting polymers are obtained
by exposing a polymer to a charge transfer agent in either gas phase or in solution.
Based on the type of charge doping, there are two types of doping conducting polymers.
a).P-doped conducting polymers: These can be obtained by doping of +’ve charge on conducting
polymers having conjugated electrons through oxidation process or these are obtained by treatment
of electrons containing conducting polymers with Lewis acid like FeCl3.
b).n-doped conducting polymers: These polymers are obtained through reduction process by
treatment of conducting polymers having electrons with reducing agents like Lewis base. These
are called as n-doped conducting polymers.
B).Extrinsically conducting polymers: The polymers exhibit the conductivity to external addition
of ingredients into them. These are two types.
1.Conductive element filled polymers: It is a polymer obtained by added or filled with conducting
elements such as carbon black, metallic fibres and metal oxides. These polymers expose good bulk
conductivity, normal cost, light in weight.
2.Blended conducting polymers: These are obtained by blending a conventional polymer be with
conducting polymer, which are changed either by physical or chemical. These possess good
physical, chemical and mechanical properties.
BIO-POLYMERS:
Biopolymer Classification
Starch or Sucrose is used as input for manufacturing Poly hydroxyl butyrate. Sugar based polymers
can be produced by blowing, injection, vacuum forming and extrusion. Lactic acid polymers
(Polyactides) are created from milk sugar (lactose) that is extracted from potatoes, maize, wheat
and sugar beet.
Starch acts as a natural polymer and can be obtained from wheat, maize and potatoes. The material
is stored in tissues of plants as one way carbohydrates. This polymer is not present in animal
tissues. It can be found in vegetables like corn, wheat and potatoes.
Synthetic compounds that are obtained from petroleum can also be used for making biodegradable
polymers such as aliphatic aromatic co-polyesters. Though these polymers are manufactured from
synthetic components, they are completely compostable and bio-degradable.
These are used for packing cigarettes. This polymer is composed of glucose and is the primary
constituent of plant cellular walls. It is obtained from natural resources like cotton, wood, wheat
and corn.
The production of biopolymer may be done either from animal products or agricultural plants.
Biopolymer Uses
These polymers play an essential role in nature. They are extremely useful in performing functions
like storage of energy, preservation and transmittance of genetic information and cellular
construction.
Sugar based polymers, such as Polyactides, naturally degenerate in the human body
without producing any harmful side effects. This is the reason why they are used for
medical purposes. Polyactides are commonly used as surgical implants.
Starch based biopolymers can be used for creating conventional plastic by extruding and
injection molding.
Biopolymers based on synthetic are used to manufacture substrate mats.
Cellulose based Biopolymers, such as cellophane, are used as a packaging material.
BIOMEDICAL POLYMERS:
Macro molecular compound obtained from natural origin. Chemical nature- polysaccharides,
protein and bacterial polyesters.
Properties: 1. Flexibility.
2.Resistance to biochemical.
3.Light weight.
4.Can be easily manufactured into products with the desired shape.
Classification: 1.Natural polymers 2. Synthetic polymers
1.Natural polymers: Natural polymers derived from living creatures are of great in the
biomaterials field.
Properties: 1. Bio-degradable.
2.Non-toxic and non-inflammatory..
3.High porous.
4.Encouraging of cell attachments and growth.
5.Easy and cheap to manufacture.
Example: Collagen, cellulose, alginates, dextrans.
2.Synthetic polymers:
Advantages: 1.Ease of manufacturability.
2.Process ability.
3.Reasonable cost.
Applications: 1.Medical disposable supplies.
2.Dental materials.
3.Dressings.
4.Polymeric drug delivery
5.Prosthetic materials.
Example: Poly tetra fluoro ethylene (PTFE), PE, Poly propylene (PP).
Classification: synthetic polymers are four types.
1. Biostable.
2. Bioerodicle
3. Water soluble
4. Other polymers.
Applications:
1. Cardiovascular applications.
2. Bones, joints and teeth.
3. Oxygen transport membranes.
4. Tissues in growth polymers.
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