Reinforcement of solid‐melt interfaces for semicrystalline polymers in a sequential two‐staged injection molding process

The solid‐melt interfaces between polyethylene (PE) and polyamide 6 (PA6) reinforced by in situ reactive compatibilization in a sequential two‐staged injection molding process has been studied in this work. The effects of the maleic anhydride grafted PE content and processing parameters, such as injection pressure, injection speed, melt temperature, and mold temperature, on the interfacial adhesion were investigated experimentally. The results of the interfacial adhesion characterized by lap shear measurement showed that the interfacial temperature and heat transfer between PE and PA6 interfaces play a very significant role in the bonding process. The fracture surfaces of the specimens prepared at different calculated interfacial temperature were investigated by scanning electron microscopy (SEM) and differential scanning calorimetry (DSC), which suggested that the fracture failure changes from adhesive to cohesive failure with increasing interfacial temperature. The contribution of crystalline parts of the in situ formed copolymers to the enhancement in interfacial adhesion also was determined by DSC analysis. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 1112–1124, 2009     

Non-destructive measurement of cavity pressure during injection molding process based on ultrasonic technology and Gaussian process

Non-destructive measurement of the cavity pressure is of great importance for monitoring, optimizing and controlling the injection molding process. However, to date, almost all researches have relied on embedded pressure probes, and holes have to be drilled in the molds. In this paper, a non-destructive cavity pressure measurement method is proposed based on ultrasonic technology and a Gaussian process. According to the pressure-volume-temperature profile, the cavity pressure of a given polymer can be treated as a function of the density and the temperature. Moreover, the cavity pressure is significantly affected by injection hydro-cylinder pressure. Ultrasonic technology is employed to detect the variation of polymer density during injection molding. The Gaussian process is adopted to model the functional relationships between the cavity pressure, the ultrasonic signal, the mold temperature and the injection hydro-cylinder pressure. Experimental results show that the proposed Gaussian process regression model has a better modeling performance than that of the neural network regression model, and the proposed measurement method is capable of measuring the cavity pressure at different processing conditions and measurement locations during injection molding. In general, the proposed method offers several advantages: (1) non-destructive, (2) flexible, (3) no wires, (4) low-cost, and (5) health and safety, so it has great application prospects in injection molding.     

Optimization of clamping force for low-viscosity polymer injection molding

Due to its low cost and high efficiency, injection molding is used for the mass production of many plastic products nowadays. However, when processing low-viscosity plastic materials, i.e., materials with an excellent fluidity, an inappropriate setting of the clamping force often results in a poor appearance and dimensional accuracy of the final product. Thus, operators usually take the upper limit of the clamping force as a default in setting up the machine in an attempt to improve the quality of the molded parts. However, such an approach shortens the machine and mold life, increases the energy consumption, and leads to poor air venting. Consequently, more scientific methods for determining the clamping force setting are required. To meet this demand, the present study proposes a clamping force search methodology for determining the optimal clamping force setting of a hydraulic cylinder clamping injection molding machine in the processing of low-viscosity plastics such as thermoplastic polyurethane (TPU) and polypropylene (PP). Based on the characteristic extracted from the sensing tie-bar elongation profile under different clamping force settings, a regression analysis on these data points is implemented to seek for an optimal clamping force. The experimental results show that for an injection molding machine with a hydraulic cylinder clamping mechanism, the effect of the mold temperature on the clamping force is sufficiently small to be ignored, which has an impact on the toggle type clamping unit. Furthermore, compared to traditional methods, the optimal clamping force obtained using the method proposed in the present study results in a significant improvement in the yield rate. Overall, the results confirm that for low-viscosity polymer resins, the optimal clamping force determined using the proposed method results in a higher and more consistent quality of the molded parts than that achieved using the proper clamping force setting for ordinary-viscosity resins.     

Measurement and quantitative analysis of fiber orientation distribution in long fiber reinforced part by injection molding

The fiber orientation distribution is one of the important microstructure variables for thermoplastic composites reinforced with discontinuous fibers. In this paper, the long fibers in the injection molded part are measured in detail by micro X-ray CT. A three dimensional (3D) structure of the sample is built and two dimensional images are generated for image analysis. The orientation tensor of fibers is calculated in the flow plane. It shows a symmetric distribution of fibers through the thickness direction, which consists of outer skin, transition zone and the core. The skin layer is so thin that it has only one layer of highly oriented fibers. The core layer also has highly oriented fibers but the direction of fibers is different from that in the skin layer. Nevertheless, the clustering of the fibers is characterized quantitatively in the core. The transition zone can be divided into two subzones by the principal directions of the tensor.     

Structure and properties of polyethylene prepared via low‐frequency vibration‐assisted injection molding

A self‐made low‐frequency vibration‐assisted injection‐molding (VAIM) device was adopted to explore the relationship between mechanical property and morphology for high‐density polyethylene injected moldings. The main processing variables for the VAIM are vibration frequency and vibration pressure amplitude, and tensile properties and morphology were investigated under different VAIM processing conditions with conventional injection molding for comparison. The moldings prepared by VAIM exhibit a very well defined laminated morphology composed of a layered structure with enhanced crystallinity. Increased with vibration frequency at constant vibration pressure amplitude, the shish‐kebab structure is exhibited in the shear layer of the specimen prepared by VAIM, whereas row nucleation lamella exists in the same layer produced by enhanced vibration pressure amplitude at a constant vibration frequency. These oriented structures and enhanced crystallinity, confirmed by scanning electron microscopy, wide‐angle X‐ray diffraction, and differential scanning calorimetry, serve to obtain stronger injection moldings. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 13–21, 2005     

Influence of pineapple leaf fiber and it's surface treatment on molecular orientation in,and mechanical properties of,injection molded nylon composites

The objective of his work is to show that pineapple leaf fiber (PALF) can be used successfully to reinforce a high melting polymer such as nylon. One of the most important barriers to the utilization of lignocellulosic materials in polymer matrix composites is their limited temperature resistance. As a consequence, they are mostly used to reinforce low melting temperature polymers such as polyethylene and polypropylene as well as polystyrene. However, this work reveals that PALF can be used to reinforce nylon. This is because of its very low lignin content. Nylon 6/66 composites containing a fixed amount of 20 wt % PALF in the form of short and fine fibers were prepared with a laboratory twin screw extruder and then injection molded. The mechanical properties of three types of PALF, i.e. untreated, alkaline- and silane-treated, were studied. Significant improvements in modulus and heat distortion temperature were obtained. The crystalline structure and orientation in the injected composites were investigated with synchrotron wide angle x-ray scattering (WAXS). It was found that both PALF and nylon crystallites oriented well along the flow direction and this is the key factor for the improvements observed.     

On the difference in material structure and fatigue properties of nylon specimens produced by injection molding and selective laser sintering

This paper describes the influence of dynamic tension/compression loading on notched and unnotched nylon specimens fabricated by Injection Molding (IM) and Selective Laser Sintering (SLS). The main objective of this work is to analyze and describe the differences in material structure and fatigue properties of as-built nylon parts produced by IM and SLM from the same polyamide 12 powder. The differences in dimensional quality, density, surface roughness, crystal structure and crystallinity are systematically measured and linked to the mechanical fatigue properties. The fatigue properties of the unnotched SLS specimens are found to be equal to those of the unnotched IM specimens. The presence of pores in the sintered samples does not lead to rapid failure, and the microvoid coalescence failure mechanism is delayed. The notched specimens show more brittle failure and increased fatigue resistance which is caused by local notch-strengthening. The results enable improved understanding of the difference in material structure and fatigue behavior of selective laser sintered and injection molded polyamide.     

Analytical review of some relevant methods and devices for the determination of the specific volume on thermoplastic polymers under processing conditions

This article reviews some of the most representative methods and devices to measure the specific volume in polymeric materials found in literature. Each method is described and a comparison between the experimental conditions and typical injection molding processing conditions is discussed. In general, the main difficulty with specific volume measurements is determination of the temperature distribution through sample thickness, particularly when achieving typical processing conditions is intended. Therefore, the necessity of developing a new device which allows direct measurements of pressure and temperature at various positions along the sample thickness in order to calculate the cooling condition was identified.     

Optimization of injection‐molding process for mechanical properties of polypropylene components via a generalized regression neural network

This study analyzed contour distortions, wear and tensile properties of polypropylene (PP) components applied in the interior coffer of automobiles. A hybrid method integrating a trained generalized regression neural network (GRNN) and a sequential quadratic programming (SQP) method is proposed to determine an optimal parameter setting of the injection‐molding process. The specimens were prepared under different injection‐molding conditions by changing melting temperatures, injection speeds, and injection pressures. Average contour distortions at six critical locations, wear and tensile properties were selected as the quality targets. Sixteen experimental runs, based on a Taguchi orthogonal array table, were utilized to train the GRNN and then the SQP method was applied to search for an optimal setting. The trained GRNN was capable of predicting average contour distortions, wear and tensile properties at various injection‐molding conditions. In addition, the analysis of variance (ANOVA) was implemented to identify significant factors for the molding process and the proposed algorithm was compared with traditional schemes like the Taguchi method and the design of experiments (DOE) approach. Copyright © 2007 John Wiley & Sons, Ltd.     

Characterization of the precolumn bio trap 500 C18 for direct injection of plasma samples in a column-switching system

Summary A new restricted access media (RAM) type of precolumn, Bio Trap 500 C₁₈, for direct injection of plasma samples in column-switching systems was evaluated with respect to the elution of plasma proteins in different mobile phases, the loading capacity of plasma samples, the chromatographic behavior during plasma injections and protein contamination of the packing and sealings. More than 95% of plasma proteins could be excluded from the precolumn within three minutes for all selected mobile phases. Quantitative analyte recoveries could be obtained by injecting plasma samples ranging from 5 to 500 μL with the analyte mass>150 ng onto a BioTrap 500 C₁₈ column (20×4 mm I.D.). One precolumn tolerated about 15 mL of plasma injection without out noticeable change in retention and pressure. Clogging of the precolumn was encountered (≥45 mL of plasma) due mainly to the adsorption of proteins on the packing. The performance of the analytical column (Kromasil C₁₈) was also examined. The column efficiency decreased by 60% after processing 45 mL plasma in total.     

A high-efficiency sample introduction system for capillary electrophoresis analysis of amino acids from dynamic samples and static dialyzed human vitreous samples

A low-volume automated injection system for the analysis of chemically complex, amino acid samples is presented. This system utilizes submicroliter sample volumes stored on a 75-μm inner diameter capillary. A pulse of positive pressure (82 kPa) is used to load nanoliter sample volumes into an in-house fabricated interface and onto a separation capillary. Residual sample solution in the interface is immediately washed away by a continuous transverse flow through the injection interface, yielding a sharp and reproducible sample plug. By performing multiple injections of a static sample, one may average the signals to yield a signal-to-noise ratio improvement of up to 4.07-fold for 20 injections compared with a theoretical maximum of a 4.47-fold improvement. Without interruption of the applied voltage, injections performed every 150 s were used to monitor the progress of the reaction of multiple amino acids with the fluorogenic dye 3-(4-carboxybenzoyl)quinoline-2-carboxaldehyde. Analysis of dialyzed clinical vitreous samples demonstrates the resolution and quantitation of arginine, lysine, leucine, glutamine, and glutamate. Observed levels are comparable with those of nonautomated injection methods and reports by others. Figure Multiple injections of fluorescently labeled human vitreous with a detailed view of a single injection (above) and with all injections segmented and averaged for signal-to-noise ratio improvement (right)     

On-line multi-bed sorption trap for VOC analysis of large-volume vapor samples: injection plug width, effects of water vapor and sample decomposition

A multibed on-line sorption trap is used to preconcentrate organic vapors from air samples and inject the analytes into a GC separation column. Injection plug widths depend on the boiling point for the lipophilic compounds and on the polarity and boiling point for the polar compounds. Injection plug widths are sufficiently small (0.7-0.8 s) as to allow the direct injection of the most volatile compounds into the GC column without the need for a second focusing device. The presence of water in the samples has an effect on the retention of polar compounds by the trap. However, this effect is reproducible for a fixed water content and so can be overcome by using calibration standards under the same conditions of humidity as the samples. The thermal decomposition of many volatile organic compounds in an on-line sorption trap during the GC analysis of air samples is examined. The results show that degradation of unstable compounds is governed by the amount of heat transferred to the compounds during desorption (i.e., applied temperature and pulse duration). The use of an on-line trap results in the immediate transfer of desorbed compounds to the analytical column, which can reduce the formation of artifacts.     

Some characteristics of a protein-coated ODS column and its use for the determination of drugs by the direct injection analysis of plasma samples

Summary It was found that an ODS column of small pore (120?) which was coated with denatured plasma proteins (protein-coated ODS) no longer adsorbed plasma proteins from aqueous solution but retained the characteristics of native ODS for small hydrophobic molecules. Elemental analysis and nitrogen desorption (BET) analysis showed that the protein-coated ODS contained ca 25 mg proteing⁻¹ dry resin and that the pore diameter or pore volume was similar to that of native ODS. The coated denatured proteins, which seemed to be adsorbed on the external surface of the porous resin, were not eluted under usual reverse-phase elution conditions. Operating as either an analytical column or a pre-column, this protein-coated ODS column was used to analyse spiked-drugs in plasma. The recovery of all the spiked-drugs (such as doxorubicin, methotrexate) was almost quantitative (98–102%) with good reproducibilities (c.v., less than 2%). The present method was useful for the determination of total, that is, free + bound-to-plasma-proteins, hydrophobic drugs in plasma in view of its accuracy and simplicity. Presented at the 15th International Symposium on Chromatography, Nürnberg, October 1984     

Routine determination of eight common anti-epileptic drugs and metabolites by high-performance liquid chromatography using a column-switching system for direct injection of serum samples

A simple and rapid high-performance liquid chromatographic method for determining eight common anti-epileptic drugs and metabolites in serum is described. A column-switching system including one analytical column and two precolumns for sample enrichment offers the possibility of directly injecting patients' sera without any pretreatment. The two precolumns are alternately switched over to avoid time loss in analysis due to the sample washing step. The samples are flushed with dilute phosphoric acid, as the purge liquid, onto the precolumns which consist of very short cartridges (length 0.5 cm) filled with spherical ODS silica gel (particle size 30 micron). The retained substances are carried over, after purification, onto the analytical column in the same direction of flow as in the flushing step. A mixture of acetonitrile and phosphoric acid--sodium phosphate buffer solution is thereby used as solvent for the gradient elution. The separation was carried out using an analytical column, which was filled with ODS material of particle size 5 micron.     

HPLC‐DAD methodology for the quantification of organic acids,furans and polyphenols by direct injection of wine samples

This article proposes a simple and sensitive HPLC method with photo‐diode array detection for the analysis of organic acids, monomeric polyphenols and furanic compounds in wine samples by direct injection. The chromatographic separation of 8 organic acids, 2 furans and 22 phenolic compounds was carried out with a buffered solution (pH 2.70) and acetonitrile as mobile phases and a difunctionally bonded C18 stationary phase, Atlantis dC18 (250×4.6 mm, 5 μm) column. The elution was performed in 12 min for the organic acids and in 60 min for the phenolic compounds, including phenolic acids, stilbenes and flavonoids. Target compounds were detected at 210 nm (organic acids, flavan‐3‐ols and benzoic acids), 254 nm (ellagic acid), 280 nm (furans and cinnamic acid), 315 nm (hydroxycinnamic acids and trans‐resveratrol) and 360 nm (flavonoids). The RSD for the repeatability test (n=5) of peak area and retention times were below 3.1 and 0.3%, respectively, for phenolics and below 1.0 and 0.2% for organic acids. The RSDs expressing the reproducibility of the method were higher than for the repeatability results but all below 9.0%. Method accuracy was evaluated by the recovery results, with averaged values between 80 and 104% for polyphenols and 97–105% for organic acids. The calibration curves, obtained by triplicate injection of standard solutions, showed good linearity with regression coefficients higher than 0.9982 for polyphenols and 0.9997 for organic acids. The LOD was in the range of 0.07–0.49 mg/L for polyphenols (cinnamic and gallic acids, respectively) and 0.001–0.046 g/L for organic acids (oxalic and lactic acids, respectively). The method was successfully used to measure and assess the polyphenolic fingerprint and organic acids profile of red, white, rosé and fortified wines.     

Adhesives: a new class of polymer coatings for surface acoustic wave sensors for fast and reliable process control applications

Fast and reliable on-line detection of organic vapors for control of chemical processes is a challenging application for a new type of analytical instruments: sensor systems based on an array of differently selective chemical sensors. In this work we present the use of mass-sensitive polymer coated surface acoustic wave sensors (SAWs). The sensors were initially coated with a standard set of polymers consisting of a known composition. But this first approach could not meet all requirements. Therefore, a new class of commercially available polymer coating, namely adhesives, was developed. The coating procedure was optimized and the aging process of the adhesives was carefully investigated. As a result the selectivity for ambitious separation problems arising from similar polarity of the components of typical solvent mixtures could be remarkably increased. The system was then applied in a real testing environment application at a chemical plant: the fast on-line control of a preparative reversed phase process HPLC (RP-PHPLC). Data from this industrial application are shown.     

Synthesis and application of hypercrosslinked polymers with weak cation-exchange character for the selective extraction of basic pharmaceuticals from complex environmental water samples

The synthesis of high specific surface area sorbents (HXLPP-WCX) in the form of hypercrosslinked polymer microspheres with narrow particle size distributions, average particle diameters around 6 μm, and weak cation-exchange (WCX) character, is described. The WCX character arises from carboxylic acid moieties in the polymers, derived from the comonomer methacrylic acid. A novel HXLPP-WCX sorbent with an attractive set of chemical and physical properties was then used in an off-line solid-phase extraction (SPE) protocol for the selective extraction of a group of basic compounds from complex environmental samples, a priority being the clean separation of the basic compounds of interest from acidic compounds and interferences. The separation power of the new sorbent for basic pharmaceuticals was compared to two commercially available, mixed-mode sorbents, namely Oasis WCX and Strata-X-CW. Under identical experimental conditions, HXLPP-WCX was found to deliver both higher capacity and better selectivity in SPE than either of the two commercially available materials. In an optimised SPE protocol, the HXLPP-WCX sorbent gave rise to quantitative and selective extractions of low μg l⁻¹ levels of basic pharmaceuticals present in 500 ml of river water and 250 ml of effluent waste water.     

Simultaneous recovery of cadmium and lead from aqueous effluents by a semi-continuous laboratory-scale polymer enhanced ultrafiltration process

Performance of a semi-continuous polymer enhanced ultrafiltration (PEUF) process has been investigated for the simultaneous recovery of cadmium and lead from binary mixtures. This method uses poly(acrylic acid) as water-soluble polymer to bind these metals. Experiments have taken place in a laboratory-scale system. Loading ratio (mg total metal ions/g polymer) and pH values for separation of cadmium and lead have been studied by means of preliminary experiments, analyzing their influence on permeate flux, metal rejection coefficients and separation factor.The proposed process includes three different stages: total retention of metal ions, selective separation and polymer regeneration. Operating pH values for total retention of metal ions and polymer regeneration processes are 5 and 2, respectively. Selective separation has been investigated working at an intermediate pH value. In this way, if a stream containing 12.5 ppm of each metal ion (1:1 in weight) is treated in the first stage, two different streams enriched in each metal ion are obtained in the second stage. Permeate stream is enriched in cadmium with a proportion near 5:1 in weight, and retentate is enriched in lead with a similar proportion.Finally, the three stages have been modelled successfully with a mathematical model based on conservation equations and chemical reactions taking place in solution.