UNIT 4-Polymeric Materials

by

MOHAMED AKBARALI
Monomers
• Monomers are atoms or small molecules that bond together to form
more complex structures such as polymers.
Examples
POLYMERIZATION
• Polymerization is a chemical reaction where monomer molecules join together to
form a polymer chain or network.
• It involves the bonding of repeating structural units called monomers to create
long chains or networks.
• This process can occur through various mechanisms, such as addition
polymerization, condensation polymerization, or ring-opening polymerization.
• Polymers, which are large molecules composed of repeating units, have diverse
applications in industries ranging from plastics and fibers to adhesives and
coatings.
Thermoset Polymers:

• Definition: Thermoset polymers are materials that undergo irreversible chemical

reactions, typically through cross-linking, during the curing process. Once formed,
they cannot be melted and reshaped because they become permanently hardened.
• Properties: They usually exhibit high strength, stiffness, and chemical resistance,
making them suitable for applications requiring durability and dimensional
stability.
• Examples:
• Epoxy Resin: Used in coatings, adhesives, electronics, and composites.
• Phenolic Resin: Found in molded products, laminates, and adhesives.
• Polyurethane: Utilized in foams, coatings, elastomers, and adhesives.
 Thermoplastic Polymers
• Definition: Thermoplastic polymers are materials that can be melted and reshaped
multiple times upon the application of heat and pressure.
• They typically do not undergo chemical cross-linking during processing.
• Properties: They often exhibit good ductility, flexibility, and processability, allowing for
easy forming and recycling.
• Examples:
• Polyethylene (PE): Commonly used in packaging, pipes, and plastic bags.
• Polypropylene (PP): Found in automotive parts, packaging, and textiles.
• Polyvinyl Chloride (PVC): Utilized in construction, healthcare products, and piping.
• Polystyrene (PS): Used in packaging, insulation, and disposable cutlery.
• Polycarbonate (PC): Found in eyeglass lenses, CDs/DVDs, and automotive parts.
 Thermoplastics: Thermosetting Polymers

Chemical These polymers have linear or branched molecular chains held These polymers have a network or cross-linked structure
Structure together by weak intermolecular forces, such as Van der Waals formed through covalent bonds. Once formed, these
forces or hydrogen bonds. bonds are generally irreversible.
Behaviour They soften when heated and solidify when cooled, making They undergo irreversible chemical reactions when
under Heat them suitable for processes like injection molding, extrusion, heated, resulting in cross-linking and hardening. Once
and thermoforming. They can be re-melted and re-shaped they are set, they cannot be remelted or reshaped
multiple times without significant degradation. without undergoing decomposition.

Mechanical They typically have lower mechanical strength and stiffness They tend to have higher mechanical strength, stiffness,
Properties compared to thermosetting polymers. However, they may and dimensional stability due to their cross-linked
exhibit toughness and flexibility depending on their molecular structure. They are often used in applications requiring
structure. high temperature resistance and excellent chemical
resistance.

Processing They can be processed using various methods like injection They are typically processed using techniques such as
Methods molding, blow molding, extrusion, and thermoforming. These compression molding or resin transfer molding. Once
processes offer flexibility in shaping and manufacturing. cured, they cannot be reshaped or reprocessed.

Applications Common applications include packaging, consumer goods, They are used in high-performance applications such as
automotive parts, pipes, and textiles. aerospace components, electrical insulators, composites,
and coatings where high temperature and chemical
resistance are required.

Recyclability They are generally more recyclable compared to thermosetting Due to their cross-linked structure, they are less
polymers since they can be melted and reshaped without recyclable and often require energy-intensive processes
significant degradation. for decomposition and reuse.
Based on Structure
• Linear Polymers: These polymers have long, straight chains without significant
branching. Examples include polyethylene (PE) and polyvinyl chloride (PVC).

• Branched Polymers: Branched polymers have side chains or branches extending from
the main chain. Examples include low-density polyethylene (LDPE) and polypropylene
(PP).

• Cross-linked Polymers: Cross-linked polymers have a network structure with covalent

bonds between polymer chains, providing high mechanical strength and stability.
Examples include epoxy resins and cross-linked polyethylene (PEX).
Based on Polymerization Mechanism

• Addition Polymers: These polymers are formed by the repeated addition of

monomers with double or triple bonds. Examples include polyethylene,
polypropylene, and polystyrene.

• Condensation Polymers: Condensation polymers are formed through the

elimination of small molecules (such as water or alcohol) during polymerization.
Examples include nylon, polyester, and polyurethane.
Based on Origin

• Synthetic Polymers: These polymers are artificially synthesized through

chemical reactions. They include a wide range of materials such as polyethylene,
PVC, polystyrene, and polytetrafluoroethylene (PTFE).

• Natural Polymers: Natural polymers occur in nature and are derived from
biological sources. Examples include proteins (e.g., silk, wool), carbohydrates
(e.g., cellulose, starch), and nucleic acids (e.g., DNA, RNA).
 Based on Chemical Composition
• Homopolymers: Homopolymers are composed of a single type of monomer repeated along the
polymer chain. Examples include polyethylene (made from ethylene monomers) and
polypropylene (made from propylene monomers).Polyvinyl chloride(made from vinyl chloride
monomers)

• Copolymers: Copolymers consist of two or more different types of monomers arranged along the
polymer chain. They can be further classified as:
• Random Copolymers: Monomers are randomly distributed along the chain (e.g., styrene-butadiene rubber).
• Block Copolymers: Monomers are arranged in blocks along the chain (e.g., styrene-butadiene-styrene block
copolymer).
• Graft Copolymers: Side chains of one monomer type are attached to the main chain composed of another
monomer type.
Specialty Polymers

• Engineering Plastics: These polymers exhibit exceptional mechanical, thermal,

and chemical properties suitable for demanding applications. Examples include
polyamide (nylon), polyethylene terephthalate (PET), and polycarbonate (PC).

• Elastomers: Elastomers are polymers with rubber-like elasticity at room

temperature. Examples include natural rubber, silicone rubber, and neoprene.

• Conducting Polymers: These polymers have electrical conductivity and are used
in electronic devices and sensors. Examples include polyaniline.
nylon

Elastomers
Proper ties and limitations of plastic material species

• Properties of Plastic Materials:

• Versatility: Plastics offer a wide range of properties depending on their composition and
structure, making them suitable for various applications.
• Lightweight: Many plastics are lightweight, which is advantageous in industries such as
automotive and aerospace.
• Chemical Resistance: Certain plastics exhibit excellent resistance to chemicals, making them
suitable for use in corrosive environments.
• Electrical Insulation: Plastics such as PVC and polyethylene have good electrical insulation
properties, making them useful in electrical and electronic applications.
• Moldability: Plastics can be easily molded into complex shapes using processes like injection
molding, extrusion, and blow molding.
• Durability: Some plastics, particularly engineering plastics like nylon and polycarbonate, offer
high mechanical strength and toughness, making them suitable for durable applications.
• Cost-Effectiveness: Many plastics are cost-effective to manufacture, making them economically
viable for mass production.
• Limitations of Plastic Materials:
• Environmental Impact: Plastics pose significant environmental challenges due to their
persistence in the environment and issues related to plastic waste and pollution.
• Low Thermal Stability: Some plastics have poor thermal stability and may degrade or melt
at relatively low temperatures, limiting their use in high-temperature applications.
• Brittleness: Certain plastics, especially those with high crystallinity or cross-linking, can be
brittle at low temperatures, reducing their impact resistance.
• UV Degradation: Exposure to ultraviolet (UV) radiation can cause degradation of plastics,
leading to color fading, embrittlement, and loss of mechanical properties.
• Flammability: Many plastics are flammable and may release toxic gases when burned,
posing fire hazards in certain applications.
• Hydrophobicity: Some plastics have low surface energy and are inherently hydrophobic,
which can make it challenging to achieve good adhesion or surface treatments.
• Processing Constraints: While plastics offer versatility in processing, some may have
limitations in terms of processing conditions, such as melt viscosity, cooling rates, and
moldability.
• Mechanical Properties: While some plastics offer high mechanical strength and toughness,
others may have limitations in terms of stiffness, impact resistance, or fatigue properties,
depending on their composition and structure.
Additives
• Additives are substances added to plastics, to modify or enhance
their properties or to facilitate their processing.
• There are several types of additives commonly used in plastics manufacturing:
Stabilizers: Stabilizers are additives used to protect plastics from degradation caused by heat,
light, oxygen, and other environmental factors. They help prevent discoloration, embrittlement,
and loss of mechanical properties during processing and use.
Plasticizers: Plasticizers are additives that increase the flexibility and workability of plastics
by reducing their stiffness and increasing their elongation. They are commonly used in PVC
(polyvinyl chloride) and other polymer formulations to make them more pliable and easier to
process.
Fillers and Reinforcements: Fillers and reinforcements are additives used to enhance the
mechanical properties of plastics, such as strength, stiffness, and impact resistance. Common
fillers include glass fibers, carbon fibers, and minerals like talc and calcium carbonate.
Pigments and Colorants: Pigments and colorants are additives used to impart color to
plastics, making them visually appealing and suitable for various applications. They can be
organic or inorganic compounds and are available in a wide range of colors and shades.
Flame Retardants: Flame retardants are additives added to plastics to reduce their
flammability and improve their fire resistance. They work by inhibiting or suppressing
the combustion process, thereby reducing the spread of flames and smoke generation.
Antioxidants: Antioxidants are additives used to prevent oxidation and degradation of
plastics caused by exposure to oxygen, heat, and light. They help maintain the
integrity of the material and extend its service life.
Antimicrobial Agents: Antimicrobial agents are additives incorporated into plastics to
inhibit the growth of bacteria, fungi, and other microorganisms on the surface of the
material. They are commonly used in applications where hygiene and cleanliness are
important, such as healthcare and food packaging.
• These are just a examples of the many types of additives used in plastics
manufacturing.
• The selection and incorporation of additives depend on the specific requirements of
the application, the properties of the base polymer, and the desired performance of the
final product.
• Proper formulation and careful consideration of additive interactions are essential to
ensure optimal performance and quality in plastic materials.
Applications of polymers
• Polymers, or plastics, have numerous applications in the automotive
industry, where their properties make them well-suited for various
components
• Interior Components: Polymers are extensively used in the interior
of vehicles due to their versatility, lightweight nature, and ability to be
molded into complex shapes.
• Common interior components made from polymers include
dashboards, door panels, consoles, seats, and trim pieces. These
components can be designed to be aesthetically pleasing, durable, and
resistant to wear and tear.
• Exterior Components: Many exterior parts of vehicles are also made
from polymers. Bumpers, body panels, grilles, spoilers, and mirror
housings are often manufactured using thermoplastics Polymers.
• Electrical and Electronic Components: Polymers play a crucial role
in the electrical and electronic systems of vehicles.
• Wiring harnesses, connectors, insulating materials, and housings for
electronic control units (ECUs) are often made from specialized
polymers with excellent electrical insulation properties and resistance
to heat and moisture.
Engine Components Application

1. Intake Manifolds: Intake manifolds are responsible for distributing air to the engine cylinders.
Polymers such as nylon (polyamide) and polyphenylene sulfide (PPS) are commonly used for intake
manifold construction due to their heat resistance, chemical stability, and ability to withstand high-
pressure conditions.
2. Valve Covers: Valve covers protect the valve train components and help contain engine oil. Polymers
like acrylonitrile butadiene styrene (ABS) and polyethylene terephthalate (PET) are often used for
valve cover applications due to their thermal resistance and ease of molding.
3. Engine Covers: Engine covers help shield various engine components from debris and contaminants
while also providing a neat appearance under the hood. Polymers such as polypropylene (PP) and
acrylonitrile butadiene styrene (ABS) are commonly used for engine cover construction due to their
lightweight nature and impact resistance.
4. Oil Pans: Oil pans store engine oil and facilitate its circulation throughout the engine. Polymers like
reinforced polyamide (PA) and polyphenylene sulfide (PPS) are used for oil pan applications because
they can withstand the temperature fluctuations and chemical exposure associated with engine oil.
5. Thermal Management Components: Polymers are increasingly being used in thermal management
components such as thermostat housings, water pump impellers, and radiator tanks. Materials like
polyetherimide (PEI) and polyphenylsulfone (PPSU) offer excellent thermal stability and can
withstand the high temperatures encountered in engine cooling systems.
Fuel Line Applications:

1. Fuel Injection Components: Polymers are used in fuel injection systems for various components
such as fuel rails, fuel injectors, and fuel pressure regulators. Materials like polyoxymethylene
(POM) and polyamide (PA) are chosen for their chemical resistance to gasoline and diesel fuels,
as well as their dimensional stability under varying operating conditions.
2. Fuel Tanks: Fuel tanks are typically made from high-density polyethylene (HDPE) or cross-
linked polyethylene (XLPE) due to their excellent chemical resistance and ability to withstand the
mechanical stresses associated with storing and transporting fuel.
3. Fuel Lines: Fuel lines transfer fuel from the tank to the engine while maintaining the integrity of
the fuel system. Polymers such as nylon (polyamide) and fluoroelastomers (e.g., Viton) are
commonly used for fuel line construction due to their resistance to fuel permeation, chemical
degradation, and temperature extremes.
4. Quick Connect Fittings: Quick connect fittings are used to join sections of fuel lines without the
need for traditional threaded connections. Polymers like acetal (POM) and polyethylene (PE) are
often used for quick connect fittings due to their durability, ease of assembly, and resistance to
fuel and environmental conditions.
Transmission systems Application
• Polymers play important roles in various aspects of automotive
transmission systems, contributing to their efficiency, durability, and
performance.
Seals and Gaskets:
• Polymers are used extensively in transmission systems for seals and
gaskets to prevent fluid leaks and contamination.
• Elastomeric materials such as nitrile rubber (NBR), fluoro elastomers
(FKM), and silicone rubber are commonly employed due to their
excellent sealing properties, resistance to fluids, and durability under
temperature and pressure fluctuations.
O-Rings and Sealing Rings:
O-rings and sealing rings made from polymers are used in various
components of the transmission, including valve bodies, pump
assemblies, and hydraulic circuits.
These components help maintain fluid pressure, prevent leaks, and
ensure proper operation of the transmission system.
Bushings and Bearings: Polymers are used in bushings and bearings
within the transmission to reduce friction and provide smooth operation.
Thermoplastics such as polytetrafluoroethylene (PTFE) and polyamide-
imide (PAI) are commonly used for their low friction coefficients, wear
resistance, and ability to withstand high loads and temperatures.
• Shift Mechanism Components: Polymers are used in the
construction of shift mechanism components such as shift forks, shift
knobs, and linkage bushings.
• Materials like acetal (POM) and polyamide (PA) are chosen for their
low friction properties, dimensional stability, and resistance to wear,
ensuring precise and smooth shifting of gears.
Fluid Reservoirs and Housings:
• Polymers are used to manufacture fluid reservoirs and housings for
components such as the transmission oil pan and filter assembly.
• High-temperature thermoplastics like polyamide (PA) and
polyphenylene sulfide (PPS) are selected for their chemical resistance,
thermal stability, and ability to withstand exposure to transmission
fluids.