A simplified method for analyzing mold filling dynamics. Part II: Extensions and comparisons with experiment

A dimensional analysis based on four parameters has been developed previously to predict injection pressure; clamp force, and bulk temperature for the injection molding of amorphous materials in center-gated disk-shaped cavities. In this paper geometric and semicrystalline-materials approximations are introduced and tested for extending the previous analysis to include multigated thin cavities and semicrystalline materials. The combination of these approximations and the previous analysis, known hereafter as the Radial Flow Method (RFM), greatly simplifies the analysis of mold filling. The geometric approximation, which is based on a simple model for the axial stress distribution in the cavity, is shown to give reasonable predictions when compared with experimental data and a numerical two-directional flow simulation for the filling of an off-center-gated rectangular cavity with acrylonitrilebutadiene-styrene copolymer (ABS). The semicrystallinematerials approximation, in which heat capacity and viscosity changes during crystallization are neglected, is shown to give good agreement with experimental data for the filling of a center-gated disk-shaped cavity with polypropylene. As an illustration, the Radial Flow Method is used to analyze the molding of a large, thin-wall automobile interior trim panel. The inlet melt temperature, mold-wall temperature, part thickness, injection rate, viscosity and gate locations are varied in a series of calculations to determine the relative effectiveness of these variables in lowering the injection pressure and Clamp force. The results obtained with the Radial Flow Method are in good agreement with those obtained by a finiteelement simulation of two-directional flow.     

Polyesters from renewable resources: Preparation and characterization

Polyesters were synthesized with monoglycerides prepared from rubber seed oil, a renewable resource. Monoglycerides were obtained by an alcoholysis method from the oil, which was neat or modified by treatments with different amounts of maleic anhydride at 230°C. The polyester resins were subsequently prepared by the condensation polymerization of the monoglycerides with phthalic anhydride. The monoglycerides and resins were characterized by spectroscopic analysis and measurements of the physicochemical properties. The chemical resistance of the polyesters was also studied. The results revealed that the polyesters prepared from the modified monoglycerides possessed better properties. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 3748–3755, 2006     

Preparation,morphology, and mechanical properties of elastomers based on α,ω‐dihydroxy‐polydimethylsiloxane/polystyrene blends

α,ω‐Dihydroxy‐polydimethylsiloxane/polystyrene (PDMS/PS) blends were prepared by the solution polymerization of styrene (St) in the presence of α,ω ‐dihydroxy‐polydimethylsiloxane (PDMS), using toluene as solvent and benzoyl peroxide (BPO) as initiator. The PDMS/PS blends obtained by this method are a series of stable, white gums, which were vulcanized to elastomers at room temperature with methyl‐triethoxysilicane (MTES). The use level of MTES was far more than the necessary amount used to end‐link hydroxy‐terminated chains of PDMS, with the excess being hydrolyzed to crosslinked networks, which were similar to SiO₂ and acted as filler. Investigations were carried out on the elastomeric materials by extraction measurement, swelling measurement, and scanning electron microscopy. The extraction data show that at each composition the amount of soluble fraction is less than expected and the difference between experimental and theoretical values becomes more and more significant as PS content increases. This is mainly due to the grafting of PS onto PDMS and the entanglement of PS in the interpenetrating polymer network (IPN), which consists of either directly linked PDMS chains or chains linked via PS grafts and is formed by free radical crosslinking of PDMS during the radical polymerization of St. PS grafted on PDMS is insoluble and PS entangled in the IPN is difficult to extract. Both render the soluble fraction to be less than expected. As the St content in preparing PDMS/PS blends increases, the probability of grafting PS onto PDMS also increases, which may subsequently produce a higher crosslinking level of PDMS networks that linked via PS grafts by radical crosslinking. As a result, not only the amount of insoluble PS increases but also PS entangled in the IPN is more difficult to extract. Scanning electron microscopy demonstrates that the elastomer system has a microphase‐separated structure and a certain amount of PS remains in the PDMS networks after extraction, which is in accordance with the extraction data. Moreover, the mechanical properties of the elastormeric materials have been studied in detail. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 3542–3548, 2004     

Polyaniline for corrosion prevention of mild steel coupled with copper

Polyaniline emeraldine base/epoxy resin (EB/ER) coating was investigated for corrosion protection of mild steel coupled with copper in 3.5% NaCl solution. EB/ER coating with 5-10 wt% EB had long-term corrosion resistance on both uncoupled steel and copper due to the passivation effect of EB on the metal surfaces. During the 150 immersion days, the impedance at 0.1 Hz for the coating increased in the first 1-40 days and subsequently remained constant above 10⁹ Ω cm², whereas that for pure ER coating fell below 10⁶ Ω cm² after only 30 or 40 days. Immersion tests on coated steel-copper galvanic couple showed that EB/ER coating offered 100 times more protection than ER coating against steel dissolution and coating delamination on copper, which was mainly attributed to the passive metal oxide films formed by EB blocking both the anodic and cathodic reactions. Salt spray tests showed that 100 μm EB/ER coating protected steel-copper couple for at least 2000 h.     

High-Strength Zirconia Fibers

Fine-grained polycrystalline zirconia fibers have been formed from an acetate precursor. The fibers contained a Y₂O₃ additive, which inhibited grain growth (grain size ≤0.5 μm) and allowed the tetragonal phase to be retained at room temperature. Fibers with diameters in the range 2 to 5 μm had strengths in the range 1.5 to 2.6 GPa.     

Velocity,temperature and conversion profiles in fixed bed catalytic reactors

Velocity and temperature profiles perpendicular to the flow direction were measured at the exit of a packed bed. The form of the profiles differed from that usually accepted in the literature. The temperature profiles showed two humps. They were simulated by means of a two-dimensional heat transfer model containing the local void fraction and velocity. The simulation of a reactor for a strongly exothermic process based upon a model accounting for radial void, velocity and temperature profiles is compared with the predictions based upon a less refined model which does not consider the effect of radial void and velocity profiles.     

Adsorption and desorption kinetics of hydrocarbons in FCC catalysts studied using a tapered element oscillating microbalance (TEOM). Part 2: numerical simulations

The factors affecting the adsorption and desorption kinetics in a TEOM are reviewed in detail with particular attention given to the assumptions required to obtain physical transport parameters from the data. Two models are presented to simulate TEOM adsorption data in the case that concentration differences down the catalyst bed can be neglected, as is appropriate when the amount of catalyst used is small, the carrier gas flowrate is large, and/or the adsorbate partial pressure is low. In the first model, the effective diffusion coefficient, D_e, is taken to be constant. In the second model, the effective diffusion coefficient is assumed to obey the Darken equation, D_e=D₀/(1−θ). The TEOM results obtained on n-hexane, n heptane, n-octane, toluene and p-xylene on a commercial FCC catalyst and on pure rare-earth exchanged zeolite Y under non-reacting conditions (373-) are analysed in detail. It is found that intracrystalline diffusion is not the limiting factor affecting the overall rates of adsorption and desorption for the systems studied. Instead, it is the transport of molecules between the adsorbed and vapour phases at the edge of zeolite crystallites that is the limiting transport step affecting the overall kinetics. For the FCC catalyst, the limiting step is the transport of molecules at the zeolite-matrix interface rather than, say, the matrix-vapour interface. Local rate constants for the desorption of the hydrocarbons at the rate-controlling interface have been obtained.