How Does thermoplastic compounds Work?

As we all know, plastic is everywhere. It’s in millions of products performing millions of functions for billions of people. From laundry baskets, to artificial joints in the human body, plastic performs and infinite number of functions. Plastics are polymers and there are a surprisingly few distinct polymer materials in the world when compared to the vast number of end uses for plastic. So how does plastic work well in millions of applications when there are only a few dozen plastic polymers? The answer is thermoplastic compounding.

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Thermoplastic compounding makes basic polymers work better. Thermoplastic compounding is a process in which base polymers are mixed with other materials to make the base material behave differently. Compounding enhances the properties of base polymers by adding other materials to them.

All this work of making polymers better takes place in an extrusion machine. Most compounding companies (including PolyVisions) use machines called twin screw extruders. These machines consist of two heated screws that melt, mix and propel plastic materials. The base polymer (usually in pellet form) is put in the extruder and melted and propelled forward inside what is called the barrel of the extruder. Other materials (generally referred to as additives) which modify the behavior of the base polymer are added along the length of the barrel and mixed in to the base polymer. By the time the materials reach the end of the barrel they are fully mixed and are then turned back into plastic pellets ready to be used to make end products.

Putting additives into thermoplastic polymers can enhance many properties including; color, impact strength, flexibility, heat and cold resistance, UV resistance, electrical conductivity, tensile strength, lubricity ad countless other characteristics. Additives may include; pigments, glass fibers, carbon nano particles, flame retardants, lubricants, other polymers, elastomers, nucleating agents, fillers, etc….

PolyVisions is a leader in reactive compounding. In this process we are able to create a chemical reaction in our twin screw extruders to produce what is called a grafted polymer. Grafted polymers are similar to co polymers in that the materials are not simply blended together, they are actually bonded to each other at the molecule level. This results in much more radical and unique property transformation of the base material. This reactive extrusion process creates a stable morphology that not only can act as an interfacial compatibilizer but also retains many of the inherent thermal and mechanical properties of the base polymers. Because the materials are molecularly bonded to each other they tend to behave with more consistency than simple blends in processing like film and sheet extrusion, thermoforming and injection molding. PolyVisions takes polyester, nylon, polyurethane, polyethylene and other materials and grafts other polymers to them to create unique new materials.

PolyVisions uses co rotating twin screw extruders to melt, mix, propel and pelletize thermoplastic materials. If you are using a thermoplastic material that needs enhanced properties, call us!

Thermoplastics are one of two main types of plastics on the market today (with thermosets comprising the other major category). Thermoplastics are unique in that their polymer bonds allow them to be heated and remolded indefinitely, making them highly recyclable, while thermosets feature permanent chemical bonds that harden after a single heating, more or less preventing heating and remolding.

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There are several different types of thermoplastics. You’re probably familiar with thermoplastics like acrylic, nylon, PVC, and Teflon, for example. How are the plastics in this category made? Are there differences between how one type of thermoplastic is produced versus other varieties?

How Are Thermoplastics Made?

By their very nature, thermoplastics can be heated and remolded again and again, depending on their chemical makeup, which means they can be “made” in a variety of ways. These plastics have to come from somewhere, however, and they typically start as components that are combined to create granules, which can be manipulated with heat and molded into products.

Thermoplastics can come from both natural and synthetic sources. For example, some thermoplastics are made from cellulosics, or cellulose fibers found in wood and cotton. Nylon, acrylic, and polyester come from petrochemicals, including petroleum- and plant-based materials.

Granules are created when the base material is heated, desired additives like dyes are mixed in, and the mixture is cooled and separated into small particles that are easy to package and transport. From there, manufacturers can reheat granules, add desired chemicals, and mold them in different ways to create a wide range of products.

Differences In Thermoplastic Manufacturing

There are a few different ways thermoplastics can be molded into desired shapes or configurations, including extrusion, injection molding, and thermoforming.

• Extrusion involves passing heated thermoplastic material through a die, or steel disk, before pressing and cutting it to create desired shapes.
• Injection molding, as the name implies, involves injecting heated thermoplastic material into a mold and allowing it to cool and harden into the prescribed shape.
• Thermoforming involves heating sheets of thermoplastic and forming them in or over molds, allowing them to cool, and then trimming away excess material.

In Conclusion

The type of production used may depend on several factors, including the type of thermoplastic being used, the product being created, and the preferences of the manufacturer. Ultimately, thermoplastics that remain unpolluted by chemical additives have the best chance of being heated, remolded, and made into new products during the recycling process.

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