Compounding

Title:
Determination of compounding technique for polymeric materials.

Abstract:
Compounding is done to provide desire thermal property, mechanical property
etc. of polymeric materials. To make the material brittle in character and to make
it useable, compounding is done. Elastomer are used for compounding. [1] Physical,
thermal, electrical or aesthetic characteristics of the plastic can be changed by
this process. Compounded materials are used in various purposes like
construction, auto, wire and cable, durables, consumer products, industrial
applications, aerospace, electrical and electronics, health care. [2]There are many
techniques for compounding materials but two roll mill technique is used in our
experiment. Only polypropylene is used to prepare polypropylene sheet for
determining different mechanical properties. Compounding also provides the
strength of the material.
Introduction:
Compounding is a process of mixing two or more different materials together. The
process of involving incorporation of ingredients into the virgin polymer is known
as ‘compounding’ of the polymer. Many polymers are cross linked by
compounding. The compounding materials are- plasticisers, vulcanizing agents,
curatives, stabilizers, fillers, coloring agents, flame retardants and lubricants etc.
Compounding consists of preparing plastic formulations by mixing or/and
blending polymers and additives in a molten state, these blends are automatically
dosed with fixed set points usually through feeders/hoppers. [4]Most polymers are
protected from thermal, oxidative and photo degradation by incorporating
appropriate stabilizers. Lubricants and process aids are added to reduce friction.
Fillers are added to impart special properties and reduce the finished product
cost. Solvent resistance can be improved by compounding with glass fiber and
other reinforcing agents. There are different machines for compounding. These
are- Banburry internal mixing mill, two-roll mixing machine, high speed stirrer,
ribbon blender, extruder etc.
There are a number of polymer possessing techniques available. These are:
1. Twin- screw extruder
2. Two-roll mill
3. Compression molder
4. Injection molder
5. High shear mixer
In our experiment two-roll mill is used because it is suitable for small scale
laboratory experiments. The relative ease of cleaning of such machines also tilts
the balance of in favor of two-roll mill.
Two-roll milling is a relatively simple method for compounding additives into
elastomeric (rubber) and certain thermoplastic polymer materials, and for
forming the resulting material into a thin sheet for subsequent molding or testing.
The mill is equipped with electrically-heated rollers capable of processing
materials at temperatures of up to 2200C. [3]
Materials:
The materials are-
1. Two –roll mill

2. Tray
3. Knife
4. Polypropylene pellet
5. Hand gloves
Procedure:
1. The roll temperature should be first adjusted to approximately 189°c.
2. The polypropylene pellets are then fed to the closed nip of two-roll mill and
rejected pellets are collected to the plate.
3. As the material forms a bond on the hotter roll, the nip is progressively
opened until all the pellets have been added.
4. The nip is then adjusted to 5 mm until a small rolling sausage or rolling bank
is formed above the nip.
5. The formed band should be part-cut, first from the edge of one side and
then from the other. The cut material should be folded so that the edge of
the cut band moves towards the center of the roll and material is exchanged
with the rolling bank to give homogeneous mixture in both longitudinal and
lateral direction.
6. After 10 or 15 minutes the two roll-mill is stopped and the rolled sheet is
cooled in ambient temperature and the pulled of the roll.
Results and discussion:
A polypropylene sheet is produced which can be further processed by different
molding techniques such as compression molding, injection molding, extrusion-
blowing, calendaring into different molds specified by ASTM. These molds are
then used for determining mechanical properties of pure polypropylene sample
by performing different tests. If different additives and fillers are added with
polypropylene during operation, then a polymer composite is made which is used
as a granular form to make desired pellets. These pellets can be further molded to
desired shape for particular use or to improve mechanical properties. In our
laboratory only polypropylene is used to make a sheet. If other polymer is mixed
with polypropylene, then high quality properties may be found.
Precaution:
1. The final composite is so much hot, so it should be handled carefully.
2. Hand gloves should be used for this experiment.
3. The pellets should be moisture free, predrying is done if necessary.
4. During the process, melt viscosity may be increased resulting in an increase
in the roll temperature which must be cooled.
Conclusion:
Compounding techniques is the most attractive industrial method for the
preparations of polymer composites due to its technological simplicity. From the
economical point of view, the use co-rating twin-screw extruder as a continuous
processing technology is preferable to melt mixing in a discontinuous kneader.
The aim of this experiment is the improvement of the mechanical properties and
materials with higher thermal conductivity in order to reduce the cooling period
of injection molded parts and blow molded parts with medium-to-high wall
thickness respectively. If in our experiment different polymers are compounded,
then different mechanical properties of compound are found. This compounding
technique is very useful to improve mechanical properties of a material.
Reference:
[1]. www.gpcaplastics.com/oldwebsite/sites/default/files-html
[2].
www.unistuttgart.de/forschung/orp/inst-profile/fak04/ikt/abteilung1.en.html
[3]. www.itrilabs.co.uk/services/polymer-processing-compounding
[4]. www.en.wikipedia.org/wiki/Plastic-compounding

Compounding

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Compounding

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Determination of compounding technique for polymeric materials.

1. Two –roll mill

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