0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page iii Modern Plastics Handbook Modern Plastics and Charles A. Harper Editor in Chief Technology Seminars, Inc. Lutherville, Maryland McGraw-Hill New York San Francisco Washington, D.C. Auckland Bogotá Caracas Lisbon London Madrid Mexico City Milan Montreal New Delhi San Juan Singapore Sydney Tokyo Toronto 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page iv Library of Congress Cataloging-in-Publication Data Modern plastics handbook / Modern Plastics, Charles A. Harper (editor in chief). p. cm. ISBN 0-07-026714-6 1. Plastics. I. Modern Plastics. II. Harper, Charles A. TA455.P5 M62 1999 668.4—dc21 99-056522 CIP McGraw-Hill Copyright © 2000 by The McGraw-Hill Companies, Inc. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a data base or retrieval system, without the prior written permission of the publisher. 1 2 3 4 5 6 7 8 9 0 DOC/DOC 0 6 5 4 3 2 1 0 ISBN 0-07-026714-6 The sponsoring editor of this book was Robert Esposito. The editing supervisor was David E. Fogarty, and the production supervisor was Sherri Souffrance. It was set in New Century Schoolbook per the MHT design by Paul Scozzari and Deirdre Sheean of McGraw-Hill’s Professional Book Group, in Hightstown, N.J. Printed and bound by R. R. Donnelley & Sons Company.. This book was printed on recycled, acid-free paper containing a minimum of 50% recycled, de-inked fiber. McGraw-Hill books are available at special quantity discounts to use as premiums and sales promotions, or for use in corporate training programs. For more information, please write to the Director of Special Sales, Professional Publishing, McGraw-Hill, Two Penn Plaza, New York, NY 10121-2298. Or contact your local bookstore. Information contained in this work has been obtained by The McGraw- Hill Companies, Inc. (“McGraw-Hill) from sources believed to be reliable. However, neither McGraw-Hill nor its authors guarantee the accuracy or completeness of any information published herein and neither McGraw- Hill nor its authors shall be responsible for any errors, omissions, or damages arising out of use of this information. This work is published with the understanding that McGraw-Hill and its authors are supplying information but are not attempting to render engineering or other pro- fessional services. If such services are required, the assistance of an appropriate professional should be sought. 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page ix Contributors Anne-Marie Baker University of Massachusetts, Lowell, Mass. (CHAP.1) Carol M. F. Barry University of Massachusetts, Lowell, Mass. (CHAP.5) Allison A. Cacciatore TownsendTarnell, Inc., Mt. Olive, N.J. (CHAP.4) Fred Gastrock TownsendTarnell, Inc., Mt. Olive, N.J. (CHAP.4) John L. Hull Hall/Finmac, Inc., Warminster, Pa. (CHAP.6) Carl P. Izzo Consultant, Murrysville, Pa. (CHAP. 10) Louis N. Kattas TownsendTarnell, Inc., Mt. Olive, N.J. (CHAP.4) Peter Kennedy Moldflow Corporation, Lexington, Mass. (CHAP. 7, SEC. 3) Inessa R. Levin TownsendTarnell, Inc., Mt. Olive, N.J. (CHAP.4) William R. Lukaszyk Universal Dynamics, Inc., North Plainfield, N.J. (CHAP. 7, SEC. 1) Joey Meade University of Massachusetts, Lowell, Mass. (CHAP.1) James Margolis Montreal, Quebec, Canada (CHAP.3) Stephen A. Orroth University of Massachusetts, Lowell, Mass. (CHAP.5) Edward M. Petrie ABB Transmission Technology Institute, Raleigh, N.C. (CHAP.9) Jordon I. Rotheiser Rotheiser Design, Inc., Highland Park, Ill. (CHAP.8) Susan E. Selke Michigan State University, School of Packaging, East Lansing, Mich. (CHAP. 12) Ranganath Shastri Dow Chemical Company, Midland, Mich. (CHAP.11) Peter Stoughton Conair, Pittsburgh, Pa. (CHAP. 7, SEC. 2) Ralph E. Wright Consultant, Yarmouth, Maine (CHAP.2) 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page xi Preface The Modern Plastics Handbook has been prepared as a third member of the well-known and highly respected team of publications which includes Modern Plastics magazine and Modern Plastics World Encyclopedia. The Modern Plastics Handbook offers a thorough and comprehensive technical coverage of all aspects of plastics materials and processes, in all of their forms, along with coverage of additives, auxiliary equipment, plastic product design, testing, specifications and standards, and the increasingly critical subject of plastics recycling and biodegradability. Thus, this Handbook will serve a wide range of interests. Likewise, with presentations ranging from terms and defin- itions and fundamentals, to clearly explained technical discussions, to extensive data and guideline information, this Handbook will be use- ful for all levels of interest and backgrounds. These broad objectives could only have been achieved by an outstanding and uniquely diverse group of authors with a combination of academic, professional, and business backgrounds. It has been my good fortune to have obtained such an elite group of authors, and it has been a distinct pleasure to have worked with this group in the creation of this Handbook. I would like to pay my highest respects and offer my deep appreciation to all of them. The Handbook has been organized and is presented as a thorough sourcebook of technical explanations, data, information, and guide- lines for all ranges of interests. It offers an extensive array of property and performance data as a function of the most important product and process variables. The chapter organization and coverage is well suited to reader convenience for the wide range of product and equipment categories. The first three chapters cover the important groups of plas- tic materials, namely, thermoplastics, thermosets, and elastomers. Then comes a chapter on the all important and broad based group of additives, which are so critical for tailoring plastic properties. Following this are three chapters covering processing technologies and 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page xii xii Preface equipment for all types of plastics, and the all important subject of auxiliary equipment and components for optimized plastics process- ing. Next is a most thorough and comprehensive chapter on design of plastic products, rarely treated in such a practical manner. After this, two chapters are devoted to the highly important plastic materials and process topics of coatings and adhesives, including surface finishing and fabricating of plastic parts. Finally, one chapter is devoted to the fundamentally important areas of testing and standards, and one chapter to the increasingly critical area of plastic recycling and biodegradability. Needless to say, a book of this caliber could not have been achieved without the guidance and support of many people. While it is not pos- sible to name all of the advisors and constant supporters, I feel that I must highlight a few. First, I would like to thank the Modern Plastics team, namely, Robert D. Leaversuch, Executive Editor of Modern Plastics magazine, Stephanie Finn, Modern Plastics Events Manager, Steven J. Schultz, Managing Director, Modern Plastics World Encyclopedia, and William A. Kaplan, Managing Editor of Modern Plastics World Encyclopedia. Their advice and help was constant. Next, I would like to express my very great appreciation to the team from Society of Plastics Engineers, who both helped me get off the ground and supported me readily all through this project. They are Michael R. Cappelletti, Executive Director, David R. Harper, Past President, John L. Hull, Honored Service Member, and Glenn L. Beall, Distinguished Member. In addition, I would like to acknowledge, with deep appreciation, the advice and assistance of Dr. Robert Nunn and Dr. Robert Malloy of University of Massachusetts, Lowell for their guidance and support, especially in selection of chapter authors. Last, but not least, I am indebted to Robert Esposito, Executive Editor of the McGraw-Hill Professional Book Group, for both his support and patience in my editorial responsibilities for this Modern Plastics Handbook. It is my hope, and expectation, that this book will serve its reader well. Any comments or suggestions will be welcomed. Charles A. Harper 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page v Contents Contributors ix Preface xi Chapter 1. Thermoplastics 1.1 1.1 Introduction 1.1 1.2 Polymer Categories 1.4 1.3 Comparative Properties of Thermoplastics 1.79 1.4 Additives 1.79 1.5 Fillers 1.82 1.6 Polymer Blends 1.83 References 1.85 Chapter 2. Thermosets, Reinforced Plastics, and Composites 2.1 2.1 Resins 2.1 2.2 Thermosetting Resin Family 2.2 2.3 Resin Characteristics 2.10 2.4 Resin Forms 2.10 2.5 Liquid Resin Processes 2.13 2.6 Laminates 2.29 2.7 Molding Compounds 2.38 References 2.88 Chapter 3. Elastomeric Materials and Processes 3.1 3.1 Introduction 3.1 3.2 Thermoplastic Elastomers (TPEs) 3.1 3.3 Melt Processing Rubbers (MPRs) 3.24 3.4 Thermoplastic Vulcanizates (TPVs) 3.26 3.5 Synthetic Rubbers 3.33 3.6 Natural Rubber 3.48 3.7 Conclusion 3.49 References 3.50 v 0267146_FM_Harper_Plastics_MHT 2/24/00 4:39 PM Page vi vi Contents Chapter 4. Plastic Additives 4.1 4.1 Introduction 4.1 4.2 Scope 4.2 4.3 Antiblock and Slip Agents 4.2 4.4 Antioxidants 4.6 4.5 Antistatic Agents 4.12 4.6 Biocides 4.16 4.7 Chemical Blowing Agents 4.19 4.8 Coupling Agents 4.23 4.9 Flame Retardants 4.26 4.10 Heat Stabilizers 4.36 4.11 Impact Modifiers 4.41 4.12 Light Stabilizers 4.46 4.13 Lubricants and Mold Release Agents 4.49 4.14 Nucleating Agents 4.54 4.15 Organic Peroxides 4.58 4.16 Plasticizers 4.62 4.17 Polyurethane Catalysts 4.66 Chapter 5.