Thursday, 2 January 2025

Rule of thumb: Water Lilies and Polymer Melts - Both Show Exponential Behaviours

Hello and welcome to the first post of the new year 2025! I hope you had a great Christmas break and I welcome you all back to a new exciting year of polymer engineering topics. 

Let us start with a Rule of Thumb post (check out my other Rules of Thumb posts here). We are living in non-linear, exponential times, which can be seen daily by the rapid advancements in technology, from Artificial Intelligence (AI), to the stock market. 

For example, if you take the compounded interest of the S&P 500, we see an exponential growth over time. Compounded interest is for Warren Buffet the key for wealth building.

For our brain it is harder to imagine exponential relations, since for us humans, linear thinking is the main "operating model"

There are lots of examples of exponential behaviour: 

  • Population growth
  • Growth of cells
  • Spread of a disease in a pandemic
  • Financial - compounding interest rates

Water lily and exponential growth

A good way to represent exponential behaviour is by looking at a pond where water lilies are growing. Water lilies double in area each day, resulting in an exponential growth. Let us imagine the following: the water lilies take 30 days to cover the whole pond. When will they cover half of the lake? 

Exactly, on the twenty-ninth day. 

Example from polymer engineering: power-law of polymer melt viscosity

Also in the plastics industry and polymer engineering, a well known example of exponential behaviour is the viscosity of polymer melts (Figure 1). 

Figure 1: Water Lilies and Polymer Melts - Both Show Exponential Behaviours.

In general, the viscosity of plastics is a function of shear rate, temperature, pressure, and chemical composition. 

At low shear rates, polymer melts show a linear behaviour (= Newtonian behaviour). In the lower shear rate region, the viscosity is independent of the shear rate.

The viscosity reaches a level which is referred to as zero-shear viscosity. 

At higher shear rates, the Power law behaviour takes over and the viscosity decreases with increasing the shear rate following a negative slope of (n-1), where n is the Power-law index.

This quantitative relationship is represented by the Power-Law model, where n is the Power-law index and k is consistency (Pa*s); Typical n values of polymer melts are between 0.2 and 0.6.

Conclusions

Exponential behaviours are dominating not only our daily life, however also the plastics industry and polymer engineering topics. It is important to have a certain awareness about such behaviours to not be suppressed and use the exponential times in our favours. 

More Rule of Thumb posts can be found under “Start here”

Latest Rule of Thumb posts:

Rule of Thumb in Polymer Injection Moulding: Fast Estimation of Cooling Time

Rule of Thumb in Polymer Engineering: How Economy of Scale Can Lower Costs

Rule of Thumb: Dealing with Weld lines in Polymer Injection Moulding

Thanks for reading & #findoutaboutplastics

Herwig Juster

Literature: 

[1] https://www.forbes.com/sites/bill_stone/2024/08/25/warren-buffetts-secret-formula-for-wealth-creation/

[2] https://www.azom.com/article.aspx?ArticleID=19175



Monday, 30 December 2024

How to win in Polymer Engineering in 2025

Hello and welcome to the last past of 2024. Today I will share with you how to win in polymer engineering in 2025 using the following three steps: 

1. Define categories where you want to grow in Polymer Engineering - for example part design and material selection

2. Set objectives for each category, what you want to achieve in 2025 - for example: be able to systematically select the optimal plastic material for my part

3. Define quantifiable key results for each objective - for example: making a material selection example once a month by using examples from real life and literature


Happy new year and all the best for 2025! 

Greetings & #findoutaboutplastics

Herwig Juster


Saturday, 21 December 2024

Seasons Greetings 2024 and Happy Holidays

Dear community, 

Seasons Greetings and Best Wishes for a Prosperous New Year! Thank you to all my regular blog readers and supporters of FindOutAboutPlastics.com.



Season Greetings 2024 - a big thank you to all my readers and supporters!

In the coming year we will have some additional posts on high performance thermoplastics selection, polymer material selection examples using the POMS-Funnel Method, Guest Interview, new plastics projects, and continue to cover topics about why plastics are the solution and not the problem. 

I am looking forward to another year of blogging! 

Have a safe and relaxing holiday season. 

All the best for 2025!

Greetings & #findoutaboutplastics

Herwig Juster

Thursday, 19 December 2024

Self-Reinforced Polyphenylene: Meet one of the stiffest unreinforced thermoplastics - Poly-para-phenylene (PPP)

Hello and welcome to another interesting class of high-performance polymers: Polyphenylenes. 

Poly-para-phenylene (PPP), a self-reinforced polymer, is a fascinating material with exceptional properties and potential applications. This polymer was first developed by Maxdem (California, USA) and market as Parmax SRP. Mississippi Polymer Technologies (MPT) acquired the technology in 2000 and then Solvay (now: Syensqo) bought it from MPT. 

Generally, self-reinforced polymers or plastics (SRPs) are thermoplastic composites made using the same material for the matrix and the reinforcement.

Chemistry and Production Process

PPP is an amorphous polymer composed of repeating para-phenylene units, forming a rigid, rod-like structure. Its synthesis is challenging due to the high reactivity of the monomers and the insolubility of the resulting polymer.  Figure 1 shows the chemical structure of the PPP rigid rod polymer.

One modern way of production method is the Suzuki polycondensation-thermal aromatization methodology, where a continuous sequence of Suzuki couplings occurs between the monomers to form a polymer. This method allows for the controlled polymerization of para-phenylene units.   

Figure 1: Chemical structure of Poly-para-phenylene (PPP) [4].

Main Properties

The backbone structure's repeating aromatic phenyl rings give PPP its exceptional strength; it has been specifically identified as one of the toughest unreinforced polymers on the market. PPP offers a number of advantageous qualities in addition to its high strength, including shape-memory properties, scratch resistance, thermal stability, and biocompatibility.

PPP exhibits remarkable properties:

  • High Thermal Stability: It possesses exceptional thermal stability, withstanding high temperatures without degradation. The glass transition temperature of PPP is 158°C and the heat deflection temperature (HDT @ 1.8 MPa) is 154°C. 
  • High Mechanical Strength: PPP exhibits exceptional mechanical strength, making it one of the stiffest and hardest thermoplastics without adding reinforcement fibers. Figure 2 compares the tensile strength and tensile modulus of PPP (PR-120 = extrusion grade; PR-250 = injection moulding grade) to PEEK, PAI, and PBI. PrimoSpire PR-120 has a tensile strength of 207 MPa and a tensile modulus of 8.3 GPa, which is twice as high as PEEK and PAI. The flexural modulus of PR-120 is with 8.3 GPa also extremely high. 

Figure 2: Tensile Strength and Tensile Modulus of PPP vs PEEK, PAI, and PBI [6].

  • Chemical Resistance: It is resistant to a wide range of chemicals, including acids, bases, and solvents. Furthermore, it is resistant to steam sterilization and is x-ray transparent. PPPs can be used as coatings in the chemical process industry and semiconductor wafer handling equipment. 
  • Self-Lubricating: PPP has self-lubricating properties, reducing friction and wear.
  • Low coefficient of thermal expansion: PPP is a quasi-isotropic material which has high strength values in almost all directions. 
  • Flame Retardancy: It is inherently flame-retardant, making it suitable for applications in fire-prone environments.
  • Metal replacement: Not only are PPPs suitable to replace different metal applications, but also fiber-reinforced plastics. 

Processing Methods

Due to its high melting point and insolubility, PPP requires specialized processing techniques:

Injection Moulding: High-temperature injection moulding is used to shape poly-para-phenylene-copolymers (PR-250) into complex components.

Extrusion: Extrusion processes, such as profile extrusion and film extrusion, are employed to produce various poly-para-phenylene-copolymers (PR-120) products.   

Machining: PPP can be machined using conventional machining techniques, although specialized tooling may be required.

Applications

PPP's unique combination of properties makes it suitable for various applications:

  • Aerospace: Components in aircraft and spacecraft, such as engine parts and structural elements. Using PPP will save weight since no reinforcements need to be added and density can be kept at 1.19 g/cm3 (glass-fiber reinforced engineering plastics have a density of typically 1.3 g/cm3).
  • Automotive: High-performance components in racing cars and other automotive applications.
  • Electronics: Heat sinks, electrical connectors, and other electronic components.
  • Medical Devices: Medical devices such as surgical instruments; PPP is able to obtain biocompatibility approvals. 
  • Industrial Machinery: Gears, bearings, and other components subjected to high stress and wear.

Trade Names and Economic Aspects

PPP is commercially available under various trade names, including:

  • Tecamax SRP (Ensinger)   
  • PrimoSpire SRP (Syensqo)   
  • Parmax (Mississippi Polymer Technologies; technology owned by Solvay; now Syensqo)

While PPP offers significant advantages, its high production cost limits its widespread use. However, as demand for high-performance materials grows, the economics of PPP production may become more favorable.

Conclusion

Poly-para-phenylene (PPP) is a remarkable polymer with exceptional properties and potential applications. Its high thermal stability, mechanical strength, chemical resistance, and self-lubricating properties make it a valuable material for demanding applications. As production techniques and demand for high-performance materials continue to evolve, PPP is poised to play an increasingly important role in various industries.

Check out my High Performance Thermoplastics selection series here: 

Introduction to High Performance Polymers (Part 1)

Polysulfides (Polyphenylene sulfide - PPS), Polysulfones (PSU, PESU, PPSU), and Polyarylates (PAR) [Part 2A]

Imide-Based Polymers (PEI, PAI, PESI, TPI, PI) and Polybenzimidazoles (PBI, PBI+PEEK, PBI+PEKK) [Part 2B]

Literature: 

[1] https://www.aimspress.com/article/doi/10.3934/matersci.2018.2.301?viewType=HTML

[2] https://pubs.rsc.org/en/content/articlelanding/2020/py/d0py00001a/unauth

[3] https://www.matweb.com/search/datasheettext.aspx?matid=67959

[4] https://www.sciencedirect.com/topics/engineering/reinforced-polymer


[6] https://www.researchgate.net/publication/275559706_Poly-para-phenylene-copolymers_PPP_for_extrusion_and_injection_moulding_Part_1_-_Molecular_and_rheological_differences
[7] https://plastic-price.com/product/solvay-specialty-polymers-primospire-pr250-polyphenylene-selfreinforce.html