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POLYMER SCIENCE AND TECHNOLOGY

Polymer is a macro molecule formed by the union of many small molecules.

Depending upon the structure, a polymer may be linear or branched.

Ex. CH2 CH2 CH2--Si O Si O - Si

Polyethylene |
Linear CH2- Si O Si O
Branched silicon resin.
Depending type of monomer, they may be homopolymer (made up of same monomer) or
Co-polymer (made up of different monomers)
O O
Ex. CH2 CH2 - n H2N (CH2)6 NH C (CH2)4 C NH -
Homopolymer Nylon 6,6
Polyethylene (Co-polymer)
POLYMERISATION: It may be defined as the process of linking or joining together small
molecules like monomers to make large molecules.
Basically there are 3 types of polymerizations.
1. Additional polymerization or Chain polymerization
2. Condensation polymerization or Step polymerization
3. Copolymerization
1. Additional polymerization or Chain polymerization: This polymerization yields an
exact multiple of basic monomeric molecules. This monomeric molecule contains one
or more double bonds. By intermolecular rearrangement of these double bonds makes
the molecule bifunctional. In this polymerization process light, heat and pressure or
catalyst is used to breakdown the double covalent bonds of monomers.
2. Condensation polymerization or Step polymerization: May be defined as a reaction
occurring between simple polar-group-containing monomers with the formation of
polymer and elimination of small molecules like water, HCl, etc. For example,
hexamethylene diamine and adipic acid condense to form a polymer, Nylon6:6.
Additional polymerization is a chain reaction converting of a sequence of three steps.
Initiation, propagation and termination.
a. Initiation step is considered to involve two reactions. The first is the production of free
radicals, usually, by the hemolytic dissociation of an initiator (or catalyst) to yield a pair of
radicals R.

I 2R (1)
(Initiator) (Free radicals)

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The second part of initiation under the addition of this radical to the just moment molecule (M)
to produce the chain initiating species M1.

R + M M1 .(2)
Free radical monomer molecule

Thus the polymerization of monomer CH2 = CHY taken in the form.

H
R + CH2 = CHY R- CH2 C
R
b. Propagation step: Consists of the growth of M1 by successive additions of large numbers of
monomer molecules according to equation.

M1+ M M2
M2+ M M3
M3+ M M4 or in general terms Mn + M Mn + 1
c. Termination step: At some time, the propagation polymer chain steps growing and
terminates.
H H H H
- CH2 C + C CH2 - CH2 C C CH2
Y Y Y Y
Disproportion in which a hydrogen atom of one radical center is transferred to another
radical center. This results in the formations of two polymer molecules, are saturated and one
unsaturated e.g.
H H H H H
CH2 C + C CH2 CH2 CH + C = C
Y Y Y Y

The two different modes of terminations can be represented in general terms by:

M*n + M*m M*n+m (Coupling)

M*n + Mm* Mn + Mm (Disproportionation)

Co-polymerization: Polymerization involving two different monomers.

Ex. Polymerization of butadiene and styrene to gave Buna S.
H
CH2 = CH CH = CH2 + nx CH2 = CH Ph -C -CH = CH CH - -CH2 CH -
1,3-butadiene (75%) Styrene(25%) H x Ph n

What is Plastic?
Plastics are the materials that show the property of plasticity and can be
moulded into any desired shape and dimensions by the application of heat and pressure.
Plastics having variety of properties are in use in present applications. The properties are low

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thermal and electrical conductivities, easy to fabricate, low specific gravity etc. The plastics
can be fabricated for large number of colours and can be used for decorative purpose. Plastics
can be used to produce complicated shapes and accurate dimensions very cheaply by moulding
process. Plastics are generally used for making automobile parts, goggle, telephones, electrical
instruments, optical instruments, household appliances etc. plastics having high wear resistance
properties can be used for making gears, bearings etc.
Merits of Plastics
1. Plastics have good shock absorption capacity compared with steel.
2. Plastics have high abrasion resistance.
3. plastics are chemically inert.
4. Plastics have high corrosion resistance compared to metals.
5. Mounding, machining, drilling etc. can be easily done on plastic materials.
6. Plastics are light in weight having specific gravity from 1 to 2, 4.
7. Plastics can be made according to the order like hard, soft, rigid, tough, brittle,
malleable etc.
8. Fabrication of plastics into desired shape and size is cheap.
9. Plastics are dimensionally stable.
10. Plastics are dont absorb water.
11. Thermal coefficient of expansion of plastic is low.
12. Excellent outer finish can be obtained on plastic products.
Demerits of Plastics
1. Plastics are soft
2. Plastics have poor ductility.
3. Resistance to heat is less.
4. Cost of plastics is high.
5. Plastics can deform under load.
THERMOSET PLASTICS: They are formed by condensation polymerization. They
have three dimensional network structures. The cross links and bonds retain their strength on
heating and hence they do not soften on heating. On prolong heating however, charming of
polymers is caused. They retain the shape and structure even on heating. Hence, they cannot be
reshaped and reused.
They are usually, hard, strong and more brittle. They cannot be reclaimed from wastes. Due to
strong bonds and cross-links they are insoluble in almost all organic solvents.

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Difference between thermo set and thermoplastics.

Plastics are materials that show the property of plasticity and can be moulded into any
desired shape and dimension of articles by the application of heat and pressure.
Thermoplastics Thermoset plastics
1. These are processed by addition 1. These are proceed by condensation
polymerization. Polymerization.
2. Softens on heating and retaining the same 2. These are infusible and insoluble
chain on cooling. mass on heating i.e., heat resistance.
3. They are along chain linear polymers 3. They are branched or cross-linked
without any branched or cross linked Polymer.
chain.
4. On repeated heating and cooling, there is 4. Some sort of chemical changes occur
On heating.
no change in chemical nature.
5. These plastics undergo purely physical [Link] Plastics undergo physical as well
As chemical process.
process.
6. By heating the plastics, thy can be 6. These plastics cannot be proceed by
heating.
proceed.
7. Waste thermoplastics can be recovered. 7. Waste thermosetting cannot be
recovered.
compounding of plastics:
Compounding of the plastics may be defined as the mixing of different
materials like plasticizers, fillers of extenders, lubricants, dies and pigments to the
thermoplastic and thermosetting plastics to increase their useful properties like strength,
toughness, etc. Resins have plasticity or binding property, but need other ingredients to be
mixed with them for fabrication into useful shapes.
Compounding of plastics:
Many plastics are virtually useless along but are converted into highly
serviceable products by combining them with a variety of additives, stabilizers etc., by the
compounding process. The exact formulation will depend upon the specific application
requirement. The different additives impart different physical properties which are used to
improve the performance of the plastic materials. Additives are widely used for thermoplastics,

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thermo sets and elastomers like phenolics or amino resins are useless alone but by the addition
of fillers, resins etc., they give a reversible products. Some of the compounding materials are
stabilizers, plasticizers, fillers, colorants or pigments, lubricants and accelerators.

Ingredients used in compounding of plastics

Some of the ingredients used in compounding of plastics are
i) Plasticizers.
ii) Fillers or extenders.
iii) Dyes and pigments.
iv) Lubricants.

i). Plasticizers
Plasticizers are substances added to enhance the plasticity of the material and to
reduce the cracking on the surface. Plasticizers are added to the plastics to increase flexibility
and toughness. Plasticizers also increase the flow property of the plastics.
Example
Dibutytyle oxalate, Castor oil and Tricresyl phosphate
ii). fillers or Extenders
Fillers are generally added to thermosetting plastics to increase elasticity and crack
resistance. Fillers improve thermal stability, strength, non combustibility, water resistance,
electrical insulation properties and external appearance.
Example
wood flour, Asbestos, Mica, Cotton, Carbon black, Graphite, Barium sulphate etc.
iii) Dyes and pigments
These are added to impart the desired colour to the plastics and give decorative effect.
iv Lubricants
These are added to prevent the plastics from sticking to the moulds.
Example
Oils, Waxes, Soaps etc.
Thus the objective of compounding is to improve the properties of the basic resin, such
that the fabrication is made easy.
Fabrication of plastics:
Many methods of fabricating plastics into desired shaped articles are employed. This
production of plastics is known as fabrication of plastics. The methods, usually depends upon
the types of resins used i.e., whether thermosetting or thermoplastic. Different fabrication
techniques are described below.
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Moulding of Plastics
Moulding of plastics comprises of forming an article to the desired shape by application
of heat and pressure to the moulding compounds in a suitable mould and hardening the
material in the mould. The method of moulding depends upon the type of resins used.
i) Compression moulding:
This method is applied to both thermoplastic and thermosetting resins. The predetermined
quantity of plastic ingredients in proper properties are filled between the two half pieces of
mould which are capable of being moved relative to each other heat and pressure are than
applied according to specifications. The containers filled with fluidized plastic. Two halves are
closed very slowly. Finally curing is done either by heating or cooling. After curing the
moulded article is taken out by opening the mould parts.

ii) Injection moulding:

In this method, the moulding plastic powder is fed into a heated cylinder from where it is
injected at a controlled rate into the tightly locked mould by means of a screw arrangement or
by a piston plunger. The mould is kept cold to allow the hot plastic to cure and become rigid.
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When the materials have been cured sufficiently, half of the mould is opened to allow the
injection of the finished article without any deformation, etc. Heating is done by oil or
electricity.

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iii) Transfer moulding:

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In this method, the principle is like injection moulding. The moulding powder is heated in a
chamber to become plastic. Later it is injected into a mould by plunger working at high
pressure through orifice. Due to this heat is developed and the plastic melts, takes the shape of
the mould.

d) Extrusion moulding:
This process is useful in the preparation of continuous wires with uniform cross section. The
heated plastic is pushed into the die with the help of screw conveyor. In the die, the plastic gets
cooled due to the exposure to atmosphere and by artificial air jets.
Extrusion moulding is used mainly for continuous moulding of thermoplastic materials into
articles of uniform cross section like tubes, rods, strips, insulated electric cables. The
thermoplastic ingredients are heated to plastic condition and then pushed by means of a screw
conveyor into a die, having the required outer shape of the article to the manufactured. Here
the plastic mass gets cooled, due to the atmospheric exposure (or artificially by air jets). A long
conveyor carries away continuously the cooled product.

L D
O R
U W
N T
J

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Moulding of insulated electric cable by vertical extrusion moulding

Differences between compression and injection moulding
techniques:
Compression Moulding Injection moulding
1. The plastic ingredient in proper 1. In this, the heated plastic is injected
Proportions are filled in between into the mould cavity from where it
the two half portions of the mould. is cooled and taken out.
These portions are moved relative
to each other and by the applying
heat and pressure, the part can be
manufactured.
2. It is applicable to both 2. It is applicable to thermoplastic
thermoplastic and thermosetting resins.

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plastic resins 3. Moulding is somewhat complicated

3. Moulding is often simpler. compared to compression moulding.
4. It is less expensive. 4. It is expensive
5. Require more operation time. 5. Require less operation time
6. Less production rate. 6. High Production rate.
7. There is no limitation to the design 7. There is limitation to the design of
of articles to be moulded. articles to be moulded.
8. High moulding cost. 8. Less moulding cost.
Polyethylene:
This can be obtained by the polymerization of ethylene at 1500 atm and a temperature 150
250 0C in presence of traces of oxygen.

Properties:
Depending upon the density, they may be LDPE and HDPE. If we use free radical initiator,
LDPE is the product while use of ionic catalysts results in the formation of HDPE.
It is a rigid, waxy white solid. Translucent. It is permeable to many organic solvents. It
crystallizes easily.
LDPE has a density 0.91 to 0.925 g/cm3
HDPE has a density 0.941 to 0.965 g/cm3
HDPE is linear and has better chemical resistance.
Uses: These are useful in the preparation of insulator parts, bottle caps, flexible bottles, pipes
etc.
LDPE is used in making film and sheeting. Pipes made of LDPE are used for both agricultural,
irrigation and domestic water line connections.
HDPE is used in manufacture of toys and other household articles.

PVC :
Poly Vinyl Chloride is obtained by heating a water emulsion of vinyl chloride in presence of a
small amount of benzoyl peroxide or hydrogen peroxide in an auto clave under pressure.

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Vinyl chloride, so needed is generally prepared by treating acetylene at 1 to 1.5 atmospheres

with hydrogen chloride at 600C to 800C in the presence of metal chloride as catalyst.

CH = CH + HCl CH2 = CH Cl
Acetylene Vinyl chloride
Properties: It occurs as a colourless rigid material.
It is having high density and low softening point.
It is resistant to light, atmospheric oxygen, inorganic acids and alkalis.
It is most widely used synthetic plastic.
Uses: It is mainly used as cable insulation, leather cloth, packing and toys.
It is used for manufacturing of film, sheet and floor covering.
PVC pipes are used for carrying corrosive chemicals in petrochemical factories.

Nylon-6,6:
It is prepared by Hexamethylene diamine and Adipic acid are polymerized in 1:1 ratio.
Properties: This is linear polymer not resistant to alkali and mineral acids.
Oxidising agents like hydrogen peroxide, potassium permanganate etc. are able to degrade the
fibres.

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Applications: Nylon-6,6 is mainly used for moulding purposes for gear bearings and making
car tyres, used for fibres etc.
This is mainly used in manufacture of tyre cord. Other uses include manufacture of carpets,
rope, fibre cloth etc.
POLYESTER
Terylene is a polyester fibre made from ethylene glycol and terephthalicacid. Terephtalic acid
required for the manufacture of Terylene is produced by the catalytic atmospheric oxidation of
p-xylene.

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Properties: This occurs as a colourless rigid substance. This is highly resistant to mineral and
organic acids but is less resistant to alkalis. This is hydrophobic in nature. This has high
melting point due to presence of aromatic ring.
Uses: It is mostly used for making synthetic fibres. It can be blended with wool, cotton for
better use and wrinkle resistance. Other application of polyethylene terephthalate film is in
electrical insulation.
TEFLON OR Poly tetra fluoro ethylene:
Teflon is obtained by polymerization of water-emulsion tetrafluoroethylene, under pressure in
presence of benzoyl peroxide as catalyst.

Properties: Due to the presence of highly electronegative fluorine atoms and the reqular
configuration of the polytetrafluoro ethylene molecule results in very strong attractive forces
between the different chains.
These strong attractive forces give the material extreame toughness, high softening point,
exceptionally high chemical-resistance towards all chemicals, high density, waxy touch, and
very low coefficient of friction, extremely good electrical and mechanical properties: It can be
machined, punched and drilled. The material, however, has the disadvantage that it cannot be
dissolved and cannot exist in a true molten state. Around 3500c, it sinters to form very viscous,
opaque mass, which can be moulded into certain forms by applying high pressures.

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Uses: as insulating material for motors, transformers, cables, wires, fittings, etc, and for
making gaskets, packing, pump parts, tank linings, chemical-carrying pipes, tubings and tanks,
etc,; for coating and impregnating glass fibres, asbestos fibres and cloths; in non-lubricating
bearings and non-sticking stop-cocks etc.

POLY URETHANES:
Poly urethanes are obtained, commercially, by treating diisocyanate and diol. For example,
Perlon-U (a crystalline polymer) is obtained by the reaction of 1,4-butane diol with 1,6-hexane
diisocyanate.
Properties: 1. polyurethanes are less stable than polyamides at elevated temperature.
2. They are characterized by excellent resistance to abrasion and solvents.
Uses: Polyurethanes are used as coatings, films, foams, adhesives and elastomers. Resilient
polyurethane fibres (spandex) are used for foundation garments and swim-suits. They also find
use as a leather substitute (corfoam). They are used to cast to produce gaskets and seals.
Bakelite:
It is prepared by condensing phenol with formaldehyde in presence of acidic/alkaline
catalyst.

The initial reaction results in the formation of O- and P- hydroxyl methyl/phenol which reacts
to form linear polymer. During modeling hexamethylene tetramine is added, which converts to
insoluble solid of cross-linked structure Bakalite.

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Applications: It is used for making electric insulator parts like switches, plugs, switch boards
etc. For making moulded articles like telephone parts cabinet of radio and television.

Silicone resins:
Silicone resins contain alternate silicone-oxygen structure, which has organic radicals attached
to silicon atoms. Thus, their structure is:
Where R= alkyl or phenyl radical
Preparation: reacting silicon with alkyl halide or silicon halide with Grignard reagent.
The reaction product is fractionally distilled to get different organo-silicon chlorides, which are
then polymerized by carefully controlled hydrolysis.
1. Dimethyl-silicon dichloride is bifunctional and can yield very long chain polymers,
E.g.
2. Trimethyl silicon chloride is monofunctional and hence, a chain-stopper. This is,
therefore, used in proportions to limit the chain-length.
3. Monomethyl silicon chlorides is trifunctional and goes cross-linking to the final
polymer. Its proportion used in polymerization, determines the amount of cross-linking
that can be obtained.
Characteristics of silicones:
1. Depending on the proportion of various alkyl silicon halides used during their
preparation, silicones may be liquids, viscous liquids, semi-solid, rubber-like and
solids.

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2. Because of silicon-oxygen links, they exhibit outstanding-stability at high temperatures,

good water resistance, good oxidation-stability, but their chemical-resistance is
generally lower than that of other plastics.
3. Their specific gravity ranges from 1.03 to 2.1.
4. Their physical properties are much less affected by variations in temperature.
5. They are non-toxic in nature.
Different types of silicones and their uses: Liquid silicones or silicone oils are relatively
low molecular-weight silicones, generally of dimethyl silicones. They possess great
wetting-power for metals, Low surface tension and show very small changes in viscosity
with temperature.
Uses:
1. They are used as high temperature lubricants, antifoaming agents, water-repellent
finishes for leather and textiles, heat transfer media, as damping and hydraulic fluids.
They are also used in cosmetics and polishes.
2. Silicone greases are modified silicone oils, obtained by adding fillers like silica, carbon
black, lithium soap, etc.
3. They are particularly used as lubricants in situations where very high and very low
temperatures and encountered.

Natural Rubber: Rubbers also known as Elastomers, they are high polymers, which
have elastic properties in excess of 300%.
Natural rubbers consist of basic material latex, which is a dispersion of isoprene. During the
treatment, these isoprene molecules polymerize to form, long-coiled chains of cis-
polyisoprene. Natural rubber is made from the saps of a wide range of plants like Hevea
brasillians and guayule.
Latex: is a milky white fluid that oozes out from the plant Hevea brasillians when a cut is
made on the steam of the plant.
The latex is diluted with water. Then acetic or formic acid is added [1kg of acid per 200kgs of
latex] to prepare coagulum. This is processed to give wither crepe rubber or smoked rubber.

Vulcanization:
Vulcanization discovered by Charles Goodyear in 1839.
It consists of heating the raw rubber at 100 1400C with sulphur. The combine
chemically at the double bonds of different rubber spring and provides cross-linking between
the chains. This cross-linking during vulcanization brings about a stiffening of the rubber by
anchoring and consequently preventing intermolecular movement of rubber springs. The
amount of sulphur added determines the extent of stiffness of vulcanized rubber. For example,
ordinary rubber (say for battery case) may contain as much as 30% sulphur.
Advantages of vulcanization:
i. The tensile strength increase.
ii. Vulcanized rubber has excellent resilience.
iii. It has boarder useful temperature range (-40 to 1000C)
iv. It has better resistance to moisture, oxidation and abrasion.
v. It is resistance to organic solvents like CCl4, Benzene petrol etc.
vi. It has only slight thickness.
vii. It has low elasticity.

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Buna S or STYRENE RUBBER:

Buna-S rubber is probably the most important type of synthetic rubber, which is produced by
copolymerization of butadiene (about 75% by weight) and styrene (25% by weight).
nCH2 = CH CH = CH2 + n CH2 = CH Ph -(-H2C -CH = CH CH --CH2 CH Ph-)n-
1,3-butadiene (75%) Styrene(25%)
Properties: Styrene rubber resembles natural rubber in processing characteristics as well as
quality of finished products.
It possesses high abrasion-resistance, high load-bearing capacity and resilience. However, it
gets readily oxidized, especially in presence of traces of ozone present in the atmosphere.
Moreover, it swells in oils and solvents. It can be vulcanized in the same way as natural rubber
either by sulphur or sulphur monochloride (S2Cl2). However, It requires less sulphur, but more
accelerators for vulcanization.
Uses: Mainly used for the manufacture of motor tyres. Other uses of these elastomers are floor
tiles, shoe soles, gaskets, foot-wear components, wire and cable insulations, carpet backing,
adhesives, tank-linings, etc.
Nitrile Rubber or GR-A or Buna N or NBR:
Preparation: It is prepared by the copolymerization of butadiene and acrylonitrile in emulsion
system.
Copolymerization
mCH2=CH-CH=CH2 + nCH2=CH--CN -(-CH2 CH=CH CH2 -)m(CH2 CH(CN)-)n-
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1,3-Butadiene Acrylonitrile Poly butadiene co-acrylonitrile

Compounding and vulcanization methods are similar to those of natural rubber.
Properties:
i. Due to the presence of cyano group, nitrile rubber is less resistance to alkalis than
natural rubber;
ii. Excellent resistance to oils, chemicals, aging (sun light). As the acrylonitrate
percentage is increased in nitrile rubber, its resistance to acids, salts, oils, solvents
etc. increases. But the low temperature resilience suffers.
iii. Compared to natural rubber, nitrile rubber (vulcanized) has more heat resistance and
it may be exposed to high temperatures.
iv. It has good abrasion resistance, even after immersion in gasoline or oils.
USES:
For making Conveyor belts, Lining of tanks, Gaskets
i. Printing rollers , Oil-resistance foams
ii. Automobile parts and high altitude air-craft components
iii. Hoses and adhesives.
Thiokol :
This also called as polysulphide rubber (or Gr-P). It can be prepared by the
condensation polymerization of sodium polysulphide (Na2Sx) and ethylene dichloride.

S S
| |
Cl CH2 - CH2 Cl + Na S S Na + Cl CH2 - CH2- Cl
Ethylene dichloride Sodium polysulphide Ethylene dichloride
S S
| |
-CH2 CH2 S S CH2 CH2-
Thiokol

It is used for the -

i. Manufacture of oils hoses, chemically resistant tubing and engine gaskets;
ii. Diaphragms and seals in contact with solvents and
iii. Printing rolls,
iv. Containers for transporting solvents and
v. Solid propellant fuels for rockets, etc.

POLY URETHANES RUBBERS:

Polyurethane or isocyanate rubber is produced by reacting polyalcohol with di-isocyanates.
n[OH-(CH2)2-OH+O=C=N-(CH2)2-N=C=O][-O-(CH2)2-O-(CO)-NH-(CH2)2-NH-(CO)-]n
Properties: Polyurethanes are highly resistant to oxidation, because of their saturated
character. They also show good resistance to many organic solvents, but are attacked by acids
and alkalis, especially concentrated and hot. The polyurethane foams are light, tought and
resistant to heat, abrasion, chemicals and weathering.

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Uses: For surface coatings and manufacture of foams and spandex fibres.

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