mechanical, chemical and flammability properties of abs/pvc blends pm dr shahrir hashim pm dr ...

265 Pages·2007·5.12 MB·English

MECHANICAL, CHEMICAL AND FLAMMABILITY
PROPERTIES OF ABS/PVC BLENDS

PM DR SHAHRIR HASHIM
PM DR AZMAN HASSAN
CHEW SAU YEN

NO. VOT PENYELIDIKAN
71820

JABATAN KEJ. POLIMER
FAK. KEJ. KIMIA DAN KEJ. SUMBER ASLI
UTM SKUDAI, JOHOR
PENGHARGAAN

Pertama sekali saya ingin mengucapkan setinggi-tinggi terima kasih kepada pihak UPP
Universiti Teknologi Malaysia kerana memberikan peruntukkan kewangan melalui Vot
71820 membolehkan saya menjalankan projek penyelidikan ini dengan jayanya.

Perhargaan yang ikhlas ditujukan kepada PM Dr Azman Hassan sebagai ahli penyelidik
serta penyelia bersama untuk pelajar master, Chew Sau Yen. Penghargaan juga ditujukan
kepada rakan-rakan yang telah menjayakan projek ini secara langsung ataupun tidak

langsung.
xiv

LIST OF FIGURES

FIGURE No. TITLE PAGE

2.1 Engineered plastics demand, 2001 8
2.2 Emulsion ABS polymerization process 12
2.3 Major property trade-offs for ABS with increasing 14
rubber level (Glenn and Cathleen, 1985)
2.4 Aotomotive Award and People’s Choice Award: 23
Unibody plastic trailer
2.5 ABS resin speeds motorbike to market 24
2.6 Industrial Enclosure Award: Printer/embosser 24
enclosure for a tabletop card personalization system
2.7 Feedstock conversion to vinyl chloride 27
2.8 Oxychlorination process 28
2.9 PVC particle morphology 29
2.10 Schematic curve showing the effect of molecular 30
weight on most mechanical properties of PVC. The
exact nature of the plot will depend on the
mechanical property selected (Donald, 1986).
2.11 PVC pumps stand up to chemicals, rough use 37
2.12 Vinyl outsoles resist harsh chemicals and oils 37
2.13 High impact PVC sparks electric fence 37
2.14 Critical Barrier Packaging Award: Package for 37
medical components
2.15 Thermoplastic worldwide forecast 38
2.16 Schematic representation of polymer degradation 44
2.17 Polymer combustion process cycle 46
xv
2.18 A typical flame involving organic fuel showing 47
decomposition region where volatilized fuel
decomposes before combustion.
2.19 Effect of antimony oxide concentration on the 49
properties of ABS containing 13wt% flame
retardant
2.20 Stress concentration around a hole (Charles, 1996) 53
2.21 Surface roughness versus fracture energy for several 54
cured epoxies
2.22 Thermal shrinkage stress directions developed by 56
differential contraction in rubber and glass during
cooling
2.23 Crazing cusp for PMMA 56
2.24 Properties versus polymer/polymer ratio in a 58
polyblend
2.25 Morphologies of a blend of polymer A (solid line) 59
and polymer B (dashed line) (a) miscible; (b)
immiscible; (c) partially miscible (Fox and Allen,
1985)
2.26 E’ – E” versus temperature for polybutadiene in 61
styrene acrylonitrile copolymer (SAN); --------
experimental; and ______ calculated: (SAN)/PBD : ○,
77/23; and ●, 56/44 (Moore, 1989)
2.27 E’ and E” vs temperature for blended system of 62
PVC and NBR of various compositions (PVC/NBR)
at 138 Hz: ○, 100/0; x, 83/17; □, 67/33; ∆,50/50; ©,
20/80; and ●, 0/100 (Moore, 1989)
3.1 Mould for injection moulding specimen 69
3.2 Izod Impact Tester 70
3.3 Dimension for Izod type test specimen 71
3.4 A schematic diagram of a DMA used to determine 72
the compatibility of the blends (Perkin-Elmer
Instrument)
xvi
3.5 DMA three point bending system 72
3.6 Photograph of SEM JSM 5610 73
3.7 Photograph of Instron universal tester 74
3.8 Typical equipment layout for oxygen index test 76
3.9 Heat distortion tester S-3 machine 77
4.1 Effect of different PVC molecular weight and 80
content on Izod impact strength of high rigidity
ABS
4.2 Effect of different PVC molecular weight and 81
content on Izod impact strength of medium impact
ABS
4.3 Effect of different PVC molecular weight and 82
content on Izod impact strength of super high
impact ABS
4.4 Effect of ABS grades and PVC content on Impact 83
strength of PVC K-58
4.5 Effect of ABS grades and PVC content on Impact 84
strength of PVC K-66
4.6 Effect of ABS grades and PVC content on Impact 85
strength of acrylic grafted PVC
4.7 Notch Izod impact strength of PVC/ABS blends at 86
23oC showing the toughness achieved by balancing
matrix ductility against PVC content (Deanin and
Moshar, 1974)
4.8 Typical dipole-dipole interaction and segments of 88
chains between molecules of PVC and SAN
4.9 DMA curves for high rigidity ABS as a function of 95
E”/E’ and tan δ
4.10 DMA curves for high rigidity ABS – PVC K66 as a 95
function of E”/E’ and tan δ
4.11 DMA curves for medium impact ABS as a function 96
of E”/E’ and tan δ
4.12 DMA curves for medium impact ABS – PVC K66 96
xvii
as a function of E”/E’ and tan δ
4.13 DMA curves for super high impact ABS as a 97
function of E”/E’ and tan δ
4.14 DMA curves for super high impact ABS - PVC K66 97
as a function of E”/E’ and tan δ
4.15 Schematic stress-whitening zone of Izod impact 99
specimen, near the edge and on the fracture surface
region
4.16A SEM micrographs of the fractured surfaces of the 101
virgin high rigidity ABS (Magnification X200)
4.16B SEM micrographs of the fractured surfaces of the 101
virgin high rigidity ABS (Magnification X2000)
4.17A SEM micrographs of the fractured surfaces of the 102
high rigidity ABS/PVC K-66 (90/10 phr/phr)
(Magnification X200)
4.17B SEM micrographs of the fractured surfaces of the 102
high rigidity ABS/PVC K-66 (90/10 phr/phr)
(Magnification X2000)
4.18A SEM micrographs of the fractured surfaces of the 103
super high impact ABS/PVC K-66 (80/20 phr/phr)
(Magnification X200)
4.18B SEM micrographs of the fractured surfaces of the 103
super high impact ABS/PVC K-66 (80/20 phr/phr)
(Magnification X2000)
4.19A SEM micrographs of the fractured surfaces of the 104
medium impact ABS/acrylic grafted PVC (85/15
phr/phr) (Magnification X200)
4.19B SEM micrographs of the fractured surfaces of the 105
medium impact ABS/acrylic grafted PVC (85/15
phr/phr) (Magnification X2000)
4.20 Forces involved in a simple beam (Vishu, 1998) 107
4.21 Effect of PVC molecular weight on heat distortion 118
temperature of high rigidity ABS
xviii
4.22 Effect of PVC molecular weight on heat distortion 119
temperature of medium impact ABS
4.23 Effect of PVC molecular weight on heat distortion 120
temperature of super high impact ABS
4.24 Determination of balance properties based on 128
impact strength and flexural modulus of high
rigidity ABS
4.25 Determination of balance properties based on 129
impact strength and flexural modulus of medium
impact ABS
4.26 Determination of balance properties based on 129
impact strength and flexural modulus of super high
impact ABS
4.27 Determination of balance properties based on 130
impact strength and flexural modulus for selected
ABS/PVC blends
xxi

LIST OF APPENDICES

APPENDIX TITLE PAGE

A A technological scheme of the production of ABS 152
polymer by the blending technique
B Comparison between suspension, mass and 153
emulsion polymerization
C A technological scheme of the production of ABS 154
polymer by grafting in emulsion
D Scheme of the production of ABS polymer by the 155
emulsion-mass technology
E Block flow diagram for PVC by suspension process 156
F PVC by mass process block flow diagram 157
G Block flow diagram for PVC by emulsion process 157
H Calculation of cost per unit volume of pure ABS 158
and ABS/PVC blends
I Published paper 170
xii

LIST OF TABLES

TABLE No. TITLE PAGE

2.1 Effect of molecular characteristics of the elastomer 13
phase and SAN copolymer forming the matrix
2.2 Historical background of PVC 26
2.3 Blends with ABS (Adam et.al, 1993) 39
2.4 Impact strength data for various PVC/ABS blends 40
(Datta and Lohse, 1996)
2.5 Impact strength data for various ABS compositions 41
blended with PVC (Datta and Lohse, 1996)
2.6 Burning characteristics, burn rates and LOI index of 45
some polymers
2.7 Properties of flame retardant ABS resin 50
2.8 Oxygen index of various metal-stabilized PVC 51
samples
3.1 Typical properties of Toyolac ABS 64
3.2 Types, trade name, manufacturer and Purpose of 65
ABS and PVC
3.3 Types, trade name, manufacturer and purpose of 66
additives
3.4 Blend formulation 67
3.5 Extrusion operating conditions 68
3.6 Injection moulding operation condition 69
3.7 Dimension measurement for Izod type test specimen 71
4.1 Transition temperature of loss tan delta for selected 93
materials
xiii
4.2 Flexural modulus for ABS/PVC blends 107
4.3 LOI index for ABS 111
4.4 LOI index for ABS/PVC blends 113
4.5 MFI data for ABS 122
4.6 MFI data for ABS obtained from Toray Plastics 122
4.7 Melt flow index for ABS/PVC blends 123
4.8 Calculation of cost per unit volume of pure ABS 126
and ABS/PVC blends
4.9 Relationship between impact properties, flexural 131
modulus, cost per unit volume and flame retardancy
of selected ABS/PVC blends