Handbook of Industrial Polyethylene and Technology Definitive Guide to Manufacturing Properties Processing Applications and Markets Set 1st Edition by Mark Spalding, Ananda Chatterjee 1119159773 9781119159773

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ISBN 10: 1119159773 

ISBN 13: 9781119159773

Author: Mark A. Spalding, Ananda Chatterjee 

This handbook provides an exhaustive description of polyethylene. The 50+ chapters are written by some of the most experienced and prominent authors in the field, providing a truly unique view of polyethylene. The book starts with a historical discussion on how low density polyethylene was discovered and how it provided unique opportunities in the early days. New catalysts are presented and show how they created an expansion in available products including linear low density polyethylene, high density polyethylene, copolymers, and polyethylene produced from metallocene catalysts. With these different catalysts systems a wide range of structures are possible with an equally wide range of physical properties. Numerous types of additives are presented that include additives for the protection of the resin from the environment and processing, fillers, processing aids, anti-fogging agents, pigments, and flame retardants. Common processing methods including extrusion, blown film, cast film, injection molding, and thermoforming are presented along with some of the more specialized processing techniques such as rotational molding, fiber processing, pipe extrusion, reactive extrusion, wire and cable, and foaming processes. The business of polyethylene including markets, world capacity, and future prospects are detailed. This handbook provides the most current and complete technology assessments and business practices for polyethylene resins.

Handbook of Industrial Polyethylene and Technology Definitive Guide to Manufacturing Properties Processing Applications and Markets Set 1st Table of contents: 

Part 1: Principles and Properties of Polyethylene
Chapter 1: An Industrial Chronology of Polyethylene
1.1 Overview
1.2 The Early Years
1.3 High Pressure Polyethylene
1.4 The Advent of High Density Polyethylene
1.5 Product and Process Proliferation
1.6 Single-Site Catalysts Arrive
1.7 The Future of LDPE
References
Chapter 2: Catalysts for the Manufacture of Polyethylene
2.1 Introduction
2.2 Synthesis of Low Density Polyethylene
2.3 Catalytic Synthesis of Polyethylene Resins
2.4 Chemistry of Catalytic Polymerization Reactions
2.5 Uniformity of Active Centers
References
Chapter 3: Ethylene Polymerization Processes and Manufacture of Polyethylene
3.1 Introduction
3.2 Processes
3.3 Resin Property and Reactor Control in Catalytic Polymerization Reactors
3.4 Economics
References
Chapter 4: Types and Basics of Polyethylene
4.1 Introduction
4.2 Low Density Polyethylene (LDPE)
4.3 Ethylene Vinyl Acetate (EVA) Copolymer
4.4 Acrylate Copolymers
4.5 Acid Copolymers
4.6 Ionomers
4.7 High Density Polyethylene (HDPE)
4.8 Ultra-High Molecular Weight HDPE (UHMW-HDPE)
4.9 Linear Low Density Polyethylene (LLDPE)
4.10 Very Low Density Polyethylene (VLDPE)
4.11 Single-Site Catalyzed Polyethylenes
4.12 Olefin Block Copolymers (OBC)
4.13 Concluding Remarks
Acknowledgments
References
Chapter 5: Molecular Structural Characterization of Polyethylene
5.1 Introduction
5.2 Molecular Weight – High Temperature GPC
5.3 Comonomer Distribution Measurement Techniques
5.4 PE Characterization with NMR
5.5 Polymer Analysis Using Vibrational Spectroscopy
5.6 Emerging Techniques
Acknowledgments
References
Chapter 6: Thermal Analysis of Polyethylene
6.1 Introduction
6.2 Differential Scanning Calorimetry (DSC)
6.3 Thermogravimetric Analysis (TGA)
6.4 Thermomechanical Analysis (TMA)
6.5 Dynamic Mechanical Analysis (DMA)
6.6 Coupled Thermal Techniques
6.7 Conclusions
References
Chapter 7: Rheology of Polyethylene
7.1 Rheology Fundamentals
7.2 Melt Rheology
7.3 Dynamic Mechanical Testing on Solids and Solid-Like Materials
7.4 Conclusions
References
Chapter 8: Processing-Structure-Property Relationships in Polyethylene
8.1 Introduction
8.2 Processing-Structure-Properties Relationship in PE Blown Films
8.3 Processing-Structure-Properties Relationship in PE Cast Films
8.4 Processing-Structure-Properties Relationship in PE Injection Molding
8.5 Processing-Structure-Properties Relationship in PE Blow Molding
8.6 Processing-Structure-Properties Relationship in PE Fibers and Nonwovens
8.7 Summary
Acknowledgments
References
Chapter 9: Mechanical Properties of Polyethylene: Deformation and Fracture Behavior
9.1 Introduction
9.2 Stress-Strain Relations for PE
9.3 True Stress-Strain-Temperature Diagrams
9.4 Time Dependency of Necking in PE
9.5 Accelerated Testing for PE Lifetime in Durable Applications
9.6 Temperature Acceleration of SCG in PE
9.7 Conclusions
References
Part 2: Processing and Fabrication of Polyethylene
Chapter 10: Single-Screw Extrusion of Polyethylene Resins
10.1 Introduction
10.2 Screw Sections and Processes
10.3 Common Problems
10.4 Process Assessments
References
Chapter 11: Twin-Screw Extrusion of Polyethylene
11.1 Introduction
11.2 History
11.3 Twin-Screw Extruder Design
11.4 Components for Compounding Lines
11.5 Twin-Screw Mixer Performance for Bi-Modal HDPE Resins
11.6 Devolatilization Extrusion
11.7 Common Problems Associated with Twin-Screw Extruders
References
Chapter 12: Blown Film Processing
12.1 Introduction
12.2 Line Rates
12.3 Monolayer Blown Film Dies
12.4 Coextrusion Blown Film Dies
12.5 Bubble Forming
12.6 Process Parameters
12.7 Blown Film Properties
References
Chapter 13: Cast Film Extrusion of Polyethylene
13.1 Description and Comparison to Blown Film Extrusion
13.2 Plasticating Extrusion
13.3 Dies
13.4 Cooling
13.5 Cast Film Processability of PE resins
13.6 Common Cast Extrusion Problems and Troubleshooting
13.7 Latest Developments
References
Chapter 14: Extrusion Coating and Laminating
14.1 Introduction
14.2 Equipment
14.3 Materials
14.4 Processing
14.5 Conclusions
References
Chapter 15: Injection Molding
15.1 Introduction
15.2 Machinery
15.3 Computer-Aided Design and Engineering
15.4 Part Design
15.5 Mold Design
15.6 Processing
15.7 Conclusions
References
Chapter 16: Blow Molding of Polyethylene
16.1 Introduction
16.2 Blow Molding Processes Using PE
16.3 Product Design with PE
16.4 Virtual Design and Performance Verification (CAE)
16.5 Design for Manufacturing (DFM) of Blow Molded PE Parts
16.6 Product Manufacturing with PE
16.7 Post Blow Molding Operations
16.8 Blow Mold Construction for PE
16.9 Auxiliary Equipment
16.10 Manufacturing Quality Control and Product Testing of PE Articles
16.11 PE Blow Molding Processing Considerations
16.12 Blow Molding Machine Manufacturers
Acknowledgments
References
Chapter 17: Rotational Molding
17.1 Introduction
17.2 Material Properties
17.3 Rotational Molding Equipment
17.4 Molds
17.5 Molds and Part Design
17.6 Processing
17.7 Conclusions
17.8 Rotational Molding Resources
References
Chapter 18: Thermoforming Polyethylene
18.1 The Thermoforming Process
18.2 Material Considerations
18.3 Thermoforming Tooling for PE
18.4 Temperature Considerations
18.5 Process Variations
18.6 Basic Forming Methods
18.7 Thermoforming Techniques
References
Chapter 19: Polyethylene Pipe Extrusion
19.1 Introduction
19.2 Pipe Performance
19.3 Extrusion Process for Solid Wall Pipe
19.4 Equipment
19.5 Typical Zone Temperature Settings
19.6 Equipment Specific to Corrugated Pipe Extrusion
19.7 Conclusions
References
Chapter 20: Polyethylene Foam Extrusion
20.1 Introduction
20.2 Solid Materials
20.3 Blowing Agents and Understanding of Transport and Rheological Properties
20.4 Batch Study and Continuous PE Foam Extrusion
20.5 PE Foam Modeling
20.6 PE Foam Properties
20.7 Recent Developments
20.8 Conclusions
Acknowledgments
References
Chapter 21: Expanded Polyethylene Bead Foam Technology
21.1 Introduction
21.2 History and Background of Bead Foam
21.3 Properties of PE Bead Foams
21.4 PE Bead Foam Material Characterization and Cell Structure
21.5 EPE Bead Foam Molding
21.6 Commercially Available Expanded PE Bead Foam Types
21.7 PE Bead Foam Molding
21.8 Stress-Strain Properties of PE Bead Foam
21.9 Benchmarking with Other Plastic Foams
21.10 PE Bead Foam Performance
21.11 PE Bead Foam Configuration
21.12 Summary
References
Chapter 22: Polyethylene Fiber Extrusion
22.1 Introduction
22.2 Fabrication Processes
22.3 Melt Spinning
22.4 Melt Blowing
22.5 Spunbonding
22.6 Solution Gel Spinning
22.7 Continuous Filaments
22.8 Staple Fibers
22.9 Flash Spinning
22.10 Electrospinning
22.11 Special Aspects
References
Chapter 23: Polyethylene Compounding Technologies
23.1 Introduction
23.2 Compounded PE Products
23.3 Blending Systems
23.4 Auxiliary Equipment
23.5 Additional Auxiliary Equipment
23.6 Compounding
23.7 Mixer Technology
23.8 Summary
References
Chapter 24: Polyethylene Modification by Reactive Extrusion
24.1 Introduction
24.2 Industrial Safety Aspects and Process Design of Reactive Extrusion
24.3 Grafting Reactions
24.4 Functional Group Modifications and Functionalization Reactions
24.5 Cross-Linking Reactions
24.6 Summary
References
Part 3: Additives for Polyethylene
Chapter 25: Degradation and Stabilization of Polyethylene
25.1 Introduction
25.2 Polyethylene Autoxidation
25.3 Polymer Stabilization
References
Chapter 26: Light Stabilization of Polyethylene
26.1 Mechanism of Photodegradation
26.2 Testing and Accelerated Weathering
26.3 Light Stabilizers
26.4 Light Stabilizers for Polyethylene
References
Chapter 27: Acid Scavengers for Polyethylene
27.1 Introduction
27.2 Basic Principles of Acid Scavenger Mechanisms
27.3 Physical and Chemical Description of Acid Neutralizers
27.4 Incorporation of Acid Neutralizers into Polyethylene
27.5 Testing Efficacy of Acid Neutralizers in Polyethylene
27.6 Example Formulations for Acid Neutralizers in Polyethylene
27.7 Common Problems Associated with Acid Neutralizer Usage
27.8 Trends
27.9 Conclusions
27.10 List of Manufacturers
References
Chapter 28: Slip Agents
28.1 Introduction
28.2 Testing
28.3 Mechanisms of These Effects
28.4 Fatty Amide Chemistries and Production
28.5 Formulation Techniques
28.6 Composition
28.7 Applications
28.8 Suppliers
References
Chapter 29: Antiblocking Additives
29.1 General Aspects
29.2 History
29.3 Details of Additives
29.4 The Nature of Blocking
29.5 Measurement Methods
29.6 Reducing Blocking
29.7 Side Effects
29.8 Examples of Uses
29.9 Toxicological Aspects
29.10 Suppliers
References
Chapter 30: Antistatic Additives for Polyethylene
30.1 Introduction
30.2 Polyethylene Overview
30.3 Chemical Structure of Antistatic Additives and Mechanism of Action
30.4 Measurements of Antistatic Activity
30.5 Effect of Different Additives on Antistatic Properties of LDPE
30.6 Suppliers of Antistatic Additives
References
Chapter 31: Antifogging Agents for Polyethylene Films
31.1 Introduction
31.2 Principle of Fog Formation on Polyethylene Films
31.3 Applications
31.4 Antifogs for Polyethylene
31.5 Evaluating Antifog Performance
31.6 Performance of Various Antifogs in Polyethylene Film
31.7 Regulatory Aspects
31.8 Future Trends
31.9 Suppliers of Antifog Agents
References
Chapter 32: Lubricants for Polyethylene
32.1 Introduction
32.2 Principles of Action
32.3 Types of Lubricants
32.4 Methods of Incorporation
32.5 Commercially Available Lubricants for UHMWPE
32.6 Special Applications
32.7 Slip Agents
References
Chapter 33: An Industrial Chronology of Polyethylene
33.1 Introduction
33.2 Common Fluorinated Polymer Processing Aids Used in Polyethylene
33.3 Benefits of Fluorinated Polymer Processing Aids in Polyethylene Melt Processing
33.4 Theory of How a Fluorinated PPA Works in the PE Extrusion Process
33.5 Effects of Other Additives and Development of Synergist Technology
33.6 Discussion and Data Related to Processing Improvements
33.7 Polyethylene Production Technology Relative to PPA Recommendations
33.8 Regulatory Information Related to Fluorinated PPAs
33.9 Partial List of Fluorinated Processing Aid Manufacturers
References
Chapter 34: Chemical Blowing Agents for Polyethylene
34.1 Introduction
34.2 Benefits of Foaming
34.3 General Requirements and Choices
34.4 Types of Chemical Blowing Agents
34.5 Methods of Incorporating Chemical Blowing Agents
34.6 Foam Processing Methods
34.7 Future Outlook for CBA in PE Foam
References
Chapter 35: Flame Retardants for Polyethylene
35.1 Introduction
35.2 Flame Retardants with Endothermic Decomposition
35.3 Flame Retardants with Gas Phase Mechanisms
35.4 Intumescent and/or Barrier Forming Flame Retardants
35.5 Radically Initiated and Accelerated Polymer Decomposition
35.6 Conclusions
References
Chapter 36: Nucleating Agents for Polyethylene
36.1 Historical Perspective of PE Nucleation
36.2 The Importance of Crystalline Orientation
36.3 Nucleating Agents that Direct Lamellar Growth
36.4 Wide-Angle X-Ray Diffraction Analysis in Extruded Sheet
36.5 Physical Property Dependence on Lamellar Orientation
36.6 Conclusions and Future Outlook
Acknowledgments
References
Chapter 37: Antimicrobial Agents for Polyethylene
37.1 Introduction: The Need for Antimicrobial Protection
37.2 Types of Microbes
37.3 Antimicrobial Chemicals
37.4 Selection of Antimicrobials for Incorporation into PE
37.5 Antimicrobial Test Methods
37.6 Processing
References
Chapter 38: Pigments and Colorants for Polyethylene
38.1 Introduction – The Fundamentals of Color
38.2 Describing and Measuring Color
38.3 Fundamentals of Pigments
38.4 Effect Pigments – Introduction
38.5 Pigment Properties and Applications
38.6 Regulatory Considerations
38.7 Colorants
38.8 List of Pigments for PE
Acknowledgments
References
Part 4: Applications of Polyethylene
Chapter 39: Fillers and Reinforcing Agents for Polyethylene
39.1 Introduction
39.2 Factors for Filler Performance
39.3 Filler Characteristics
39.4 Structure
39.5 Interfacial Interactions and Interphase
39.6 Surface Modification
39.7 Micromechanical Deformations
39.8 Properties
39.9 Application
39.10 Conclusions
References
Chapter 40: Flexible Packaging Applications of Polyethylene
40.1 Introduction
40.2 Flexible Packaging Market
40.3 Utilization of Polyethylene for Flexible Packaging
40.4 Functions of Flexible Packaging
40.5 Conversion of Materials into Pouches or Bags
40.6 Secondary Packaging
40.7 Tertiary Packaging
40.8 End-of-Life (EOL) Considerations
References
Chapter 41: Rigid Packaging Applications
41.1 Introduction
41.2 Blow Molded Bottles and Containers
41.3 Injection Molded Containers, Lids, Caps, and Closures
41.4 Thermoformed Containers
41.5 Personal Care, Medical, and Pharmaceutical Packaging
41.6 Rigid Polyethylene Packaging and Sustainability
References
Chapter 42: Pipe and Tubing Applications of Polyethylene
42.1 Introduction
42.2 History
42.3 HDPE Application to Water Supply and Structural Pipe
42.4 MDPE and its Application to Potable Water and Natural Gas
References
Chapter 43: Wire and Cable Applications of Polyethylene
43.1 Overview
43.2 Communications Applications
43.3 PE in Power Cable Applications
43.4 Specialty Applications
43.5 Additive Requirements
43.6 Extrusion Processing
43.7 Summary
References
Chapter 44: Medical Applications of Polyethylene
44.1 Introduction
44.2 Regulatory Considerations
44.3 Medical Packaging
44.4 Implants
44.5 Recent Developments
44.6 Summary
References
Chapter 45: Automotive Applications for Polyethylene
45.1 Fuel Tanks and Systems
45.2 PE Elastomers as Impact Modifiers for TPO
45.3 Miscellaneous PE Applications
45.4 Emerging PE Applications
References
Chapter 46: Textile, Hygiene, Health, and Geosynthetic Applications of Polyethylene
46.1 Introduction
46.2 Applications
46.3 Hygiene
46.4 Health
46.5 Geosynthetics
46.6 Closing Remarks
References
Chapter 47: Applications of Polyethylene Elastomers and Plastomers
47.1 Brief History of Elastomers
47.2 Definitions
47.3 Formulations and Compounding
47.4 Compounding Methodology
47.5 Article Conversion
47.6 Applications
47.7 Summary
References
Part 5: The Business of Polyethylene
Chapter 48: Product Regulatory Considerations for Polyethylene
48.1 Introduction
48.2 Risk Assessment Fundamentals
48.3 International Legislation for Food Packaging Safety
48.4 Drinking Water Regulation
48.5 Global Chemical Inventories and Control Laws
48.6 Restricted Chemicals Legislation
48.7 Conclusions
References
Chapter 49: Sustainability and Recycling of Polyethylene
49.1 Types of Polyethylene
49.2 Properties of HDPE and LDPE
49.3 Applications for HDPE and LDPE
49.4 Recycling of HDPE and LDPE
49.5 Sustainability of Polyethylene and Polyethylene Production
References
Chapter 50: Bio-Polyethylene and Polyethylene-Biopolymer Blends
50.1 Environmentally Friendly Synthesis
50.2 Properties of Bio-PE
50.3 Manufacturers of Bio-PE
50.4 Formulations of Bio-PE
50.5 Special Uses
50.6 Biodegradation
References
Chapter 51: The Business of Polyethylene
51.1 Introduction
51.2 Raw Materials
51.3 Basic Materials
51.4 PE Producers
51.5 Polyolefins Polymerization Technologies
51.6 PE Grades and Applications
51.7 PE Markets
51.8 PE Processors
51.9 PE End Users
51.10 Competitiveness – Olefins and Polyolefins
51.11 Current Developments
51.12 Conclusions

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