Rheology and Processing of Polymeric Materials: Volume 2: Polymer Processing Book

Remarks on Volume 2 xvii

Part I Processing of Thermoplastic Polymers

1 Flow of Polymeric Liquid in Complex Geometry 3

1.1 Introduction 3

1.2 Flow through a Rectangular Channel 4

1.2.1 Flow Patterns in a Rectangular Channel 4

1.2.2 Extrudate Swell from a Rectangular Channel 6

1.2.3 Analysis of Flow though a Rectangular Channel 6

1.3 Flow in the Entrance Region of a Slit Die 20

1.4 Flow through a Converging or Tapered Channel 25

1.5 Exit Region Flow 32

1.6 Flow through a Channel Having Small Side Holes or Slots 35

1.7 Analysis of Flow in a Coat-Hanger Die 40

1.7.1 Analysis of Flow in the Manifold 42

1.7.2 Analysis of Flow in the Coat-Hanger Section 45

1.8 Summary 48

Problems 49

Notes 53

References 54

2 Plasticating Single-Screw Extrusion 56

2.1 Introduction 56

2.2 Performance of Plasticating Single-Screw Extruders for Semicrystalline Polymers 57

2.2.1 Analysis of the Solid-Conveying Section 59

2.2.2 Analysis of the Melting Section 60

2.2.3 Analysis of Melt-Conveying Section 67

2.2.4 Comparison of Prediction with Experiment 68

2.3 Performance of Fluted Mixing Heads in a Plasticating Single-Screw Extruder 85

2.3.1 Analysis of the Flow through the Maddock Mixing Head 86

2.3.2 Comparison of Prediction with Experiment 90

2.4 Performance of Plasticating Barrier-Screw Extruders 98

2.4.1 Stability of the Solid Bed in Plasticating Barrier-Screw Extruder 102

2.4.2 Analysis of the Performance of Plasticating Barrier-Screw Extruders 107

2.4.3 Comparison of Prediction with Experiment 111

2.5 Performance of Plasticating Single-Screw Extruders for Amorphous Polymers 114

2.5.1 The Concept of Critical Flow Temperature 115

2.5.2 Analysisof Plasticating Extrusion of Amorphous Polymers 116

2.5.3 Comparison of Prediction with Experiment 119

2.6 Summary 128

Notes 129

References 130

3 Morphology Evolution in Immiscible Polymer Blends during Compounding 132

3.1 Introduction 132

3.2 Morphology Evolution in Immiscible Polymer Blend during Compounding in an Internal Mixer 134

3.2.1 Morphology Evolution in Blends Consisting of Two Semicrystalline Polymers 137

3.2.2 Morphology Evolution in Blends Consisting of Two Amorphous Polymers 140

3.2.3 Morphology Evolution in Blends Consisting of an Amorphous Polymer and a Semicrystalline Polymer 144

3.3 Morphology Evolution in Immiscible Polymer Blend during Compounding in a Twin-Screw Extruder 154

3.3.1 Morphology Evolution in Blends Consisting of Two Amorphous Polymers 156

3.3.2 Morphology Evolution in Blends Consisting of an Amorphous Polymer and a Semicrystalline Polymer 161

3.4 Stability of Co-Continuous Morphology during Compounding 169

3.5 Summary 174

Appendix Theoretical Interpretation of Figure 3.34 177

Notes 179

References 179

4 Compatibilization of Two Immiscible Homopolymers 181

4.1 Introduction 181

4.2 Experimental Observations of Compatibilization of Two Immiscible Homopolymers Using a Block Copolymer 186

4.2.1 A/B/(A-block-B) Ternary Blends 187

4.2.2 A/B/(A-block-C) Ternary Blends 194

4.2.3 A/B/(C-block-D) Ternary Blends 210

4.3 Reactive Compatibilization of Two Immiscible Polymers 224

4.4 Summary 229

Notes 231

References 232

5 Wire-Coating Extrusion 235

5.1 Introduction 235

5.2 Analysis of Wire-Coating Extrusion 236

5.3 Experimental Observations 245

5.4 Summary 253

Problems 255

Notes 256

References 256

6 Fiber Spinning 257

6.1 Introduction 257

6.2 Fiber Spinning Processes 258

6.2.1 Melt Spinning Process 258

6.2.2 Wet Spinning Process 260

6.2.3 Dry Spinning Process 262

6.2.4 Other Fiber Spinning Processes 263

6.3 High-Speed Melt Spinning 268

6.3.1 Experimental Observations of High-Speed Melt Spinning 269

6.3.2 Modeling of High-Speed Melt Spinning 273

6.3.3 Model Prediction and Comparison with Experiment 284

6.4 Spinnability 294

6.5 Summary 296

Problems 297

Notes 300

7 Tubular Film Blowing 305

7.1 Introduction 305

7.2 Processing Characteristics of Tubular Film Blowing 307

7.2.1 Kinematics and Stress Field in Tubular Film Blowing 308

7.2.2 Tensile Stresses at the Freeze Line and Processing-Property Relationships in Tubular Film Blowing 311

7.3 Analysis of Tubular Film Blowing Including Extrudate Swell 317

7.3.1 Force Balance Equation 319

7.3.2 Energy Balance Equation 322

7.3.3 Viscoelastic Constitutive Equation 323

7.3.4 Analysis of Tubular Film Blowing in the Extrudate Swell Region 326

7.3.5 Analysis of Tubular Film Blowing in the Stretching Region 329

7.3.6 Model Predictions and Comparison with Experiment 330

7.4 Tubular Film Blowability 341

7.5 Summary 346

Problems 348

Notes 348

References 349

8 Injection Molding 351

8.1 Introduction 351

8.2 Flow of Molten Polymer through a Runner 354

8.3 Injection Molding of Amorphous Polymers 358

8.3.1 Flow Patterns during Mold Filling 358

8.3.2 Governing System Equations for Mold Filling of Amorphous Polymers 363

8.3.3 Molecular Orientation during Mold Filling and Residual Stress in Injection Molded Articles 366

8.4 Injection Molding of Semicrystalline Polymers 370

8.4.1 Crystallization during Injection Molding 370

8.4.2 Governing System Equations for Injection Molding of Semicrystalline Polymers 372

8.4.3 Morphology of Injected-Molded Semicrystalline Polymers 373

8.5 Summary 375

Notes 376

References 376

9 Coextrusion 379

9.1 Introduction 379

9.2 Coextrusion Die Systems 382

9.2.1 Feedblock Die System for Flat-Film or Sheet Coextrusion 382

9.2.2 Multimanifold Die System for Flat-Film or Sheet Coextrusion 383

9.2.3 Feedblock Die system for Blown-Film Coextrusion 384

9.2.4 Rotating-Mandrel Die System for Blown-Film Coextrusion 386

9.3 Polymer-Polymer Interdiffusion across the Initially Sharp and Flat Interface 388

9.3.1 Polymer-Polymer Interdiffusion under Static Conditions 389

9.3.2 Polymer-Polymer Interdiffusion in the Shear Flow Field 400

9.4 Nonisothermal Coextrusion 407

9.5 Summary 417

Appendix Derivation of Equation (9.36) 418

Problems 419

Notes 421

References 421

10 Foam Extrusion 424

10.1 Introduction 424

10.2 Solubility and Diffusivity of Gases in a Molten Polymer 425

10.2.1 Solubility of Gases in a Molten Polymer 425

10.2.2 Diffusivity of Gases in a Molten Polymer 433

10.3 Bubble Nucleation in Polymeric Liquids 443

10.3.1 Experimental Observations of Bubble Nucleation 446

10.3.2 Theoretical Considerations of Bubble Nucleation in Polymer Solutions 462

10.4 Foam Extrusion 468

10.4.1 Processing-Property-Morphology Relationship in Profile Foam Extrusion 469

10.4.2 Processing-Property Relationships in Sheet Foam Extrusion 482

10.5 Summary 487

Problems 488

Notes 489

References 489

Part II Processing of Thermosets

11 Reaction Injection Molding 495

11.1 Introduction 495

11.2 Analysis of Reaction Injection Molding 497

11.2.1 Main Flow 498

11.2.2 Front Flow 501

11.2.3 Cure Stage 502

11.2.4 Chemorheological Model 503

11.3 Conversion and Temperature Profiles during Mold Filling 503

11.4 Summary 512

Problems 513

Notes 514

References 515

12 Pultrusion of Thermoset/Fiber Composites 517

12.1 Introduction 517

12.2 Effect of Mixed Initiators on the Cure Kinetics of Unsaturated Polyester 519

12.3 Cure Kinetics of Unsaturated Polyester/Fiber Composite 525

12.4 Analysis of the Pultrusion of Thermoset/Fiber Composite 528

12.4.1 General System Equations 528

12.4.2 System Equations with an Empirical Kinetic Model 530

12.4.3 System Equations with a Mechanistic Kientic Model 531

12.5 Conversion and Temperature Profiles in a Pultrusion Die 531

12.6 Summary 540

Problems 541

References 542

13 Compression Molding of Thermoset/Fiber Composities 544

13.1 Introduction 544

13.2 Thickening Behavior of Unsaturated Polyester 547

13.3 Effect of Pressure on the Curing of Unsaturated Polyester 552

13.4 Analysis of Compression Molding of Unsaturated Polyester/Glass Fiber Composite 561

13.5 Time Evolution of Temperature during Compression Molding of Unsaturated Polyester/Glass Fiber Composite 564

13.6 Summary 568

References 569

Author Index 571

Subject Index 578