ME332 재료가공(Materials Processing)
Polymer Processing Technology
Tai Hun Kwon
DEPARTMENT OF MECHANICAL ENGINEERING
POHANG UNIVERSITY OF SCIENCE & TECHNOLOGY
2003 by T. H. Kwon
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Why Polymer Processing?
Advances in
Various plastic materials
Plastic based composites
Merits of using plastic components:
Strength to weight ratio is high reduce weight
Good formability Versatile complicated parts
Good for Mass production
Replace metallic components with plastic components
Conventional Applications:
1. Electric appliances, Automobile components, etc.
2. Precision optical products such as CD, DVD, Lenses
Futuristic Applications
Microstructures,
Microfluidics,
Nanotechnology, etc.
Multidisciplinary research for the futuristic goal is in need and thus
asks us to understand macromolecular behavior in more detail.
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Examples of Futuristic Applications
1. Chaotic mixing in screw extrusion
(a)
(b) (c)
(d) (e)
Fig. 0.1 Chaos screw proposed by Kim and Kwon(1995): (a) schematic of
chaos screw, mixing experimental results at zones (b) without and (c) with
barrier,
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2. Chaotic Micromixers (Barrier embedded Micromixer, BEM)
Barrier Slanted grooves
30µm
240µm
40µm
60µm
9µm
100µm
(a)
Barrier Hyperbolic point Elliptic point
Elliptic points
(b) At the zone with barrier (c) At the zone with
on slanted grooves only slanted grooves
Fig.0.2 Barrier Embedded Micromixer: (a) schematic view, (b) and (c)
corresponding cross-sectional velocity fields. Slanted grooves cause the cross-
sectional velocity field of (c) and the velocity
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Experimental observation
Phenolphthalein
Flow
NaOH Interface
(a)
(b)
(c)
Fig. 0.3 Mixing experimental results of: (a) T-channel, (b) only slanted grooves
and (c) BEM at the indicated positions at Q = 10.0µl/min (Re ≈ 0.457). Only
the phenolphthalein portion at the interface between phenolphthalein and NaOH
streams shows red color.
Numerical simulations by Finite Element Method
At the entrance 1st cycle 2nd cycle 5th cycle
7th cycle 10th cycle 13th cycle 15th cycle
Fig. 0.4 Cross sectional view of mixing patterns after several cycles in BEB
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3. Microlens arrays
(a)
(b)
(c)
Fig. 0.5 Proposed fabrication process and result: (a) Step 1, X-ray irradiation,
(b) Step 2, thermal treatment, and (c) fabricated microlenses by a modified
LIGA process.
Fig. 0.6 Relaxation of free volume: relation between temperature and specific
volume of polymer.
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(a) TH = 105°C (b) TH = 115°C
Fig. 0.7 Predicted microlens shapes (nominal diameter of 1500µm) in
comparison with experimental ones (solid) at two different heating
temperatures of (a) 105°C (b) 115°C: predictions without considering the
relaxation process (dotted), and with considering the relaxation process
(broken).
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Microlenses
2
Seed layer
deposition
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Ni electroplating
Mold insert
(a) (b)
Fig. 0.8 Fabrication of the microlens mold insert for the hot embossing: (a)
sequence of steps and (b) photographs of Ni-electroplated mold insert.
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Fig. 0.9 Surface profiles of the injection molded φ 500µm micro-lenses (PC)
with mold insert.
(a) f200 µm microlens (b) f200 µm microlens
array mold insert array embossed PMMA
(c) f300 µm microlens (d) f300 µm microlens
mold insert embossed PC
Fig. 0.10 SEM images of the mold insert and replicated polymers
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PART I. POLYMER PROCESSING TECHNOLOGIES
Extrusion Process
Single Screw Extruders
Twin Screw Extruders
Injection Molding Process
Compression Molding Process
Transfer Molding Process
Blow Molding Process
Thermoforming Process
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1.1 Screw extrusion process
Fig. 1.1 A single screw extruder
Fig. 1.2 A conventional single screw
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Fig. 1.3 Corotating twin screw elements
Fig. 1.4 Counter-rotating twin screw elements
Fig. 1.5 Static mixers
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1.2 Injection molding process
Fig. 1.6 An injection molding machine
Fig. 1.7 Reciprocating screw injection molding
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1.3 Compression molding, Transfer molding
Fig. 1.8 Schematic view of the compression molding process
Fig. 1.9 Two stages of the injection/Compression molding process
Fig. 1.10 Schematic view of the transfer molding process
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1.4 Blow molding process
Fig. 1.11 Schematic view of the blow molding process
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1.5 Thermoforming process
Fig. 1.12 Schematic view of the thermoforming process
(a) Vacuum forming, (b) Plug-assisted vacuum forming
