ThermoPlastic Elastomer
Thermoplastic elastomers (TPE) are a unique combination of properties of both plastics and rubber. These materials have both the flexibility and elasticity of rubber and the thermal processability of plastics. This unique combination has made TPEs one of the most popular materials in various industries.
TPE are typically composed of two or more polymers linked together in a block or branched structure. This structure allows them to have both elastomeric and thermoplastic properties.
Applications of TPEs
TPEs are used in a variety of industries due to their unique properties, including:
Automotive industry: Interior parts of cars such as gear levers, seat covers, and under-hood parts.
Medical industry: Medical gloves, medical tubing, and other medical equipment.
Sports industry: Athletic shoes, balls, and other sports equipment.
Packaging: Flexible packaging, airbags, and protective packaging.
Home use: Home appliances, toys, and other consumer products.
Electronic industry: Protective coverings for cables and electronic components.
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ThermoPlastic Elastomer
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Emulsion
Polyvinyl chloride (PVC) is a widely used thermoplastic polymer made from the polymerization of vinyl chloride monomers (VCM).
PVC is produced by polymerizing vinyl chloride monomers using different techniques.one of these techniques is emulsion polymerization.PVC (Polyvinyl Chloride) emulsion grade is a type of PVC resin produced via the emulsion polymerization process. This method results in very fine particles of PVC, which are ideal for applications requiring a smooth, uniform texture.
StructurePVC emulsion grade is a fine-particle polymer produced through emulsion polymerization, resulting in a high molecular weight material with excellent dispersion and film-forming properties. Its structure consists of small, porous particles that readily absorb plasticizers, making it ideal for flexible and soft applications. The polymer chains in emulsion-grade PVC are densely packed, contributing to its superior adhesion, smooth surface finish, and enhanced mechanical properties. Unlike suspension-grade PVC, which has larger and more irregular particles, emulsion-grade PVC exhibits a uniform texture and lower gelation temperature, making it suitable for applications such as synthetic leather, vinyl flooring, medical gloves, and textile coatings. This structural composition allows for easy processing in plastisols and organosols, ensuring a high degree of flexibility, durability, and aesthetic appeal in the final products.
PropertiesPVC emulsion grade is a fine-particle, high molecular weight polymer known for its excellent dispersion and film-forming properties. It has a small particle size, typically in the range of 0.1–2.0 microns, which allows for superior surface finish and enhanced mechanical strength in end applications. This grade of PVC exhibits good plasticizer absorption, making it ideal for flexible and soft products such as synthetic leather, flooring, coatings, and dip-molded goods. It also offers high viscosity in plastisol form, ensuring uniform application in coatings and pastes. Additionally, PVC emulsion grade demonstrates good chemical resistance, durability, and thermal stability, making it suitable for a wide range of industrial and consumer applications.
Applications of PVC Emulsion Grade:
- Synthetic Leather – Used in the production of artificial leather for furniture, automotive upholstery, and fashion accessories.
- Coatings & Paints – Provides a smooth and durable finish in coatings for fabrics, wallpapers, and flooring.
- Dipping Products – Used in medical gloves, toys, and tool grips due to its excellent film-forming properties.
- Flooring & Wall Coverings – Applied in vinyl flooring, wall coverings, and laminates for enhanced durability and aesthetics.
- Printing Inks – Improves adhesion and flexibility in specialized printing inks.
- Automotive & Construction – Utilized in automotive interiors and flexible membranes in construction applications.
Advantages of PVC Emulsion Grade:✔ Excellent Film Formation – Ensures smooth, uniform coatings and films. ✔ High Plasticizer Absorption – Enables flexibility and softness in final products. ✔ Good Chemical & Weather Resistance – Resistant to moisture, chemicals, and UV exposure, enhancing durability. ✔ Fine Particle Size – Allows superior surface finish and controlled viscosity in plastisol applications. ✔ Versatility – Suitable for a wide range of industrial and consumer applications.
Disadvantages of PVC Emulsion Grade:✖ Environmental Concerns – Contains plasticizers and additives that may cause pollution or health risks if not properly managed. ✖ Processing Sensitivity – Requires precise temperature control during processing to prevent degradation. ✖ Lower Heat Resistance – Can soften or degrade at high temperatures, limiting its use in extreme conditions. ✖ Limited Biodegradability – Like other PVC types, it does not decompose easily, posing disposal challenges.
Expandable PolyStyrene (EPS)
Expanded Polystyrene (EPS) is a rigid, closed cell, thermoplastic foam material produced from solid beads of polystyrene, which is polymerised from styrene monomer and contains an expansion gas (pentane) dissolved within the polystyrene bead. Each solid polystyrene bead contains small amounts of gas which expand when heat (in the form of steam) is applied, thus forming closed cells of EPS. These expanded cells occupy approximately 40 times the volume of the original polystyrene bead, and so with a second heat treatment using a mould, large EPS blocks can be moulded into specific customised shapes.
Expanded PolyStyrene structureThe structure of Expanded Polystyrene (EPS) consists of tiny, closed-cell foam beads made of polystyrene. These beads are expanded using heat, causing them to expand up to 50 times their original size. Also each bead contains air pockets.
Expanded PolyStyrene propertiesExpanded polystyrene (EPS) is found to be the most commonly used polymer core. This is because it is lightweight, resistant to moisture and also it has a long life. Studies have concluded that softening of EPS starts when exposed to temperatures ranging from 100°C to 120°C. In the process of flashovers, EPS melted about 160°C and then vaporized, producing poisonous gases at a temperature of 275°C. EPS is an inert, low density hydrocarbon-derived thermoplastic which contains several spherical beads with 2 percent polystyrene and 98 percent air
Expanded PolyStyrene applicationsBuilding and Construction-EPS is widely used in the building and construction industry due to its insulation properties. It can be used:
- As insulated panel systems for facades, walls, roofs and floors in buildings.
- As flotation material in the construction of marinas and pontoons.
- As a lightweight fill in road and railway construction.
- in the packaging of foodstuffs such as seafood, fruit, and vegetables.
- to produce food service containers like drink cups, food trays, and clamshell containers.
expanded polystyrene advantages
- lightweight
- water-resistant
- easily manufactured
- Energy Efficient
- high Durability and Longevity
expanded polystyrene disadvantages
- vulnerability to compression
- limited fire resistance
- non-biodegradable
Extrusion
The extrusion process is basically designed to continuously convert a soft material into a particular form. The heart of this processing/fabrication machine is a screw conveyer. It carries the cold plastic material (in granular or powdered form) forward by the action of the screw and squeezes it, and, with heat from external heaters and the friction of viscous flow, changes it to a molten stream (refer to Figure 1). As it does this, it develops pressure on the material, which is highest right before the molten plastic enters the die. The screen pack, consisting of a number of fine or coarse mesh gauzes supported on a breaker plate and placed between the screw and the die, filter out dirt and unfused polymer lumps. The pressure on the molten plastic forces it through an adapter and into the die, which dictates the shape of the final extrudate.
Hot extrusionHot extrusion is a hot working process, which means it is done above the material’s recrystallization temperature to keep the material from work hardening and to make it easier to push the material through the die. Most hot extrusions are done on horizontal hydraulic presses that range from 230 to 11,000 metric tons . Pressures range from 30 to 700 MPa , therefore lubrication is required, which can be oil or graphite for lower temperature extrusions, or glass powder for higher temperature extrusions. The biggest disadvantage of this process is its cost for machinery and its upkeep.
Cold extrusionCold Extrusion is a push-through compressive forming process with the starting material (billet/slug) at room temperature. During the process, however, the deforming material undergoes deformation heating (conversion of deformation work to heat) to several hundred degrees. Typically, a punch is used to apply pressure to the billet enclosed, partially or completely, in a stationary die.
Advantages of Extrusion:
- Cost-effective for large-scale production with minimal waste.
- Versatile: Supports various materials and shapes.
- Customizable: Additives and design flexibility.
- Consistent quality and scalable production.
- Energy-efficient and integrates with other processes.
Disadvantages of Extrusion:
- Material limitations: Not all polymers are suitable.
- High setup costs: Equipment and dies are expensive.
- Dimensional variability: Cooling shrinkage and die swell.
- Shape limitations: Intricate designs are challenging.
- Quality control issues: Surface defects and material inconsistencies.
- Post-processing needs: Cutting, finishing, or coating required.
- Environmental concerns: Energy use and plastic waste.
Application of extrusion1.Construction Industry
- Pipes and tubing (e.g., PVC pipes, drainage systems).
- Window and door profiles (e.g., uPVC frames).
- Insulation materials (e.g., foam boards, weather seals).
- Plastic films and sheets (e.g., food packaging, shrink wraps).
- Containers and trays.
- Seals and gaskets.
- Wire and cable insulation.
- Interior trims and protective sheathing.
- Straws, ropes, and garden hoses.
- Plastic profiles for furniture or appliances.
- Wire and cable coatings.
- Conduits for electrical wiring.
- Catheters, tubing, and other medical-grade profiles.
- Conveyor belts and guides.
- Protective linings for machinery.
- Irrigation tubing and films.
- Greenhouse covers.
General Purpose PolyStyrene (GPPS)
General purpose polystyrene, abbreviated as “GPPS”, is made from the styrene monomer polymer through a suspension process. It is a solid product that is compressed into granules to produce a wide range of products. This material has high clarity and transparency. GPPS is a rigid and transparent thermoplastic polymer that is highly versatile and easy to process. GPPS has excellent electrical insulation properties, is lightweight, and has good dimensional stability. It is commonly used in a wide range of applications such as packaging, household items, and office supplies.
StructureGPPS is a thermoplastic polymer that is made from styrene monomer. The chemical structure of GPPS consists of a linear chain of styrene monomer units that are joined together by covalent bonds. The properties of GPPS can be modified by copolymerizing it with other monomers such as acrylonitrile, butadiene, Zinc or methyl methacrylate.
General Purpose Polystyrene propertiesGPPS is highly resistant to moisture and has good electrical insulation properties. IT is a brittle material with low-impact strength. It has a tensile strength of 50-60 MPa and a flexural modulus of 2,200-2,500 MPa. GPPS has a glass transition temperature (Tg) of 85-105°C and a melting temperature (Tm) of 200-240°C. It has a heat deflection temperature (HDT) of 70-80°C under a load of 0.45 MPa.
ApplicationGeneral Purpose Polystyrene (GPPS) is a versatile thermoplastic material that finds use in a variety of applications. Here are some of the most common applications of GPPS: Packaging GPPS is a popular choice for packaging materials due to its excellent transparency, rigidity, and moldability. It is commonly used to make food containers, disposable cutlery, and CD cases. GPPS is also used in the production of blister packs, which are commonly used to package pharmaceuticals. Consumer Products GPPS is used in the production of various consumer products due to its excellent electrical insulation properties, lightweight, and dimensional stability. It is commonly used to make toys, cosmetic packaging, and household items such as hangers, trays, and organizers. Building and Construction GPPS is used in the construction industry due to its excellent insulation properties, lightweight, and dimensional stability. It is commonly used to make insulation foam boards, window frames, and light fixtures. GPPS is also used in the automotive industry to make various parts such as instrument panels, door panels, and grilles due to its excellent moldability and dimensional stability.
Advantages
- excellent moldability
- good insulator of heat and electricity
- versatile and cost-effective
- clear visibility of the contents inside
- Good dimensional stability
Disadvantages
- low-impact strength
- low thermal stability
- non-biodegradable
High Density PolyEthylene Film (HDPE)
High Density Polyethylene (HDPE for short) is a thermoplastic polymer derived from petroleum with a generalized chemical formula (C2H4)n. The HDPE formula represents the repeating monomer unit of ethylene and forms a poly-ethylene molecular chain. HDPE is distinct from other forms of polyethylene in that its side chain branching frequency is lower than other polyethylene types, where hdpe film is commonly referred to as a “linear” chain. This linear structure allows high density polyethylene film to pack together more tightly and is the reason for its impressive material characteristics.
Structure
The structure of High-Density Polyethylene (HDPE) is characterized by long, linear chains of repeating ethylene units (–CH₂–CH₂–) with minimal or negligible branching. This linear configuration allows the polymer chains to pack closely together, resulting in a high degree of crystallinity (up to 80-90%) and a dense molecular arrangement. The compact structure enhances intermolecular van der Waals forces, giving HDPE its high tensile strength, rigidity, and chemical resistance. The lack of branching, achieved through polymerization methods like Ziegler-Natta or metallocene catalysis, is a defining feature that differentiates HDPE from other polyethylene types, such as Low-Density Polyethylene (LDPE). This tightly packed and highly organized structure makes HDPE a robust and durable material, widely used in industrial and consumer applications.Properties
- High Strength-to-Density Ratio: While lightweight, HDPE exhibits excellent tensile strength, making it suitable for heavy-duty applications.
- Chemical Resistance: It is resistant to a wide range of chemicals, acids, and bases, ensuring durability in corrosive environments.
- Low Moisture Absorption: HDPE’s low water absorption ensures its effectiveness in moisture-prone applications.
- Flexibility and Impact Resistance: It withstands impact and environmental stress, even under extreme conditions.
- Thermal Resistance: HDPE maintains integrity in a broad temperature range, making it ideal for outdoor and industrial uses.
Applications
HDPE plastic is used in a laundry list of applications, as it is currently one of the most versatile plastic materials worldwide. Its strength, impact and corrosion resistance, chemical profile, and other valuable characteristics make it an ideal product material for various industries. Below is a brief list of some of the many uses of HDPE plastic:- Corrosion-resistant piping, HDPE sheet, and stock material
- Fuel tanks
- Food and beverage containers, plastic bottles, milk jugs, cups, etc.
- Shampoo/conditioner bottles, ointment tubes, personal care product containers, etc.
- Trash cans, recycle bins, plastic containers, etc.
- Bread bags, cereal box liners, food storage containers, etc.
- Laundry detergent bottles
- Recycled plastic lumber and composites
- Medical equipment
- 3D printing filament
- Boating components
- Coax cable insulators
- Sewage mains
- Pyrotechnic components
Advantages
- High strength-to-weight ratio
- Low friction coefficient and low moisture absorption
- High impact strength, resistant to dents and scratches
- Mold, mildew, rotting, mineral acids/bases, soil, and weather-resistant
- Resistant to chemicals, water, solvents, acids, detergents, and cleaning fluids
- Very malleable when heated and experiences medium to low shrinkage
- Easily recycled
- Can be sterilized via boiling, does not harbor bacteria well, and is dishwasher safe
- Replaces heavier materials in some applications
- Cost-effective
Disadvantages
- In certain forms, it can be flammable as it is a petroleum-based product
- Exhibits high thermal expansion
- Weak to oxidizers and chlorinated hydrocarbons
- Difficult to bond
- Sensitive to stress-cracking in suboptimal environments
High Impact PolyStyrene (HIPS)
High-impact polystyrene (HIPS) is the rubberreinforced polystyrene plastic which exhibits significantly enhanced impact strength compared to pure polystyrene, while maintaining the main properties of polystyrene such as ductility and reasonable price. It has been widely used in daily equipment. There are two phases in HIPS: polystyrene continuous phase and rubber-dispersed phase. HIPS is usually synthesized by bulk free radical polymerization.
High Impact PolyStyrene StructureStructure: HIPS consists of long chains of polystyrene in which fine particles of a rubber polymer are distributed. These particles act as a kind of “shock absorber” and prevent cracks from propagating in the polymer.
High Impact PolyStyrene propertieshigh impact polystyrene hips has a combination of properties that make it a versatile and widely used material. It is rigid, impact-resistant, lightweight, easy to process, and has a low melting point. HIPS is also resistant to chemicals, oils, and grease. HIPS has a tensile strength of 24.8 MPa (3,600 psi) and tensile modulus of 1.8 GPa (261 ksi) according to ASTM standards, this plastic is capable of withstanding enough force to make it a suitable choice for the packaging industry, and many other products as well.
ApplicationsFrom the grocery store to the packaging plant to the factory floor, this versatile plastic is a staple across all sorts of sectors. Some examples are:
- Knives, forks, and spoons in the food grade industry use HIPS Plastic.
- Elongated profiles found on display stands are created from HIPS Plastic.
- Containers and trays in the packaging industry
- HIPS plastic makes lightweight tubing and profiles common to household goods
- high impact polystyrene uses creates molded parts used to assemble toys
High Impact PolyStyrene advantages
- more environmentally friendly than other plastics
- High Impact Resistance
- Highly Malleable
- Ability to Paint
- Affordable Price
High Impact PolyStyrene disadvantages
- HIPS is vulnerable to degradation by many chemicals, including solvents, acids, and alkalis.
- HIPS has a low-temperature resistance and can become brittle at low temperatures.
- HIPS has limited resistance to UV light and can become yellow and brittle over time when exposed to UV light.
- HIPS has poor flame resistance and will ignite and burn easily.
Styrenic Block Copolymers (TPS)
Styrenic Block Copolymers (TPS) are a class of thermoplastic elastomers (TPEs) composed of alternating hard and soft polymer segments. The hard segments are made of polystyrene (PS), while the soft segments consist of rubber-like elastomers such as polybutadiene (PB) or polyisoprene (PI). This structure gives TPS materials the elasticity of rubber while maintaining the easy processability of thermoplastics.
StructureStyrenic block copolymers (TPS) have a phase-separated structure composed of alternating hard and soft polymer segments. The hard segments consist of polystyrene (PS) domains, which provide strength, rigidity, and thermal stability, while the soft segments are made of elastomeric materials such as polybutadiene (PB), polyisoprene (PI), or ethylene-butylene (EB), contributing to flexibility and elasticity. These block copolymers form a physical crosslinking network where the polystyrene blocks aggregate into discrete domains, acting as physical anchors that hold the material together, while the rubbery segments remain continuous and provide elasticity. This unique morphology allows TPS materials to behave like thermoset elastomers at room temperature but soften and flow when heated, making them fully thermoplastic and easily reprocessable. The phase separation between the polystyrene and elastomeric segments gives TPS its characteristic combination of strength, flexibility, and processability, making it widely used in applications requiring both durability and soft-touch properties.
PropertiesStyrenic block copolymers (TPS) exhibit a unique combination of elasticity, strength, and processability due to their phase-separated structure. They have excellent flexibility and rubber-like elasticity, allowing them to stretch and recover their shape without permanent deformation. Their mechanical properties include good tensile strength and impact resistance, making them durable for various applications. TPS materials have moderate heat resistance, generally performing well below 100°C, and are resistant to many oils, greases, and chemicals, enhancing their stability in demanding environments. They also have good adhesion properties, making them suitable for overmolding onto other plastics. Unlike thermoset rubbers, TPS materials are thermoplastic, meaning they can be melted, reshaped, and recycled multiple times, improving manufacturing efficiency and sustainability. They also provide a soft-touch feel, making them ideal for grips, handles, and other ergonomic applications. Additionally, TPS offers good weather resistance, especially in formulations like SEBS, which enhance UV and oxidation stability. These combined properties make TPS widely used in automotive, medical, consumer goods, and adhesive applications.
Application
- Automotive Industry:
- Soft-touch interior components (dashboards, door panels)
- Seals, gaskets, and vibration dampeners
- Grip pads and protective coatings
- Consumer Goods:
- Handles and grips for tools, toothbrushes, and razors
- Sports equipment, shoe soles, and protective gear
- Flexible packaging and stretchable films
- Medical Applications:
- Medical tubing and syringe plungers
- Overmolded soft-touch medical devices
- Flexible, biocompatible components
- Adhesives and Sealants:
- Pressure-sensitive adhesives (PSAs)
- Hot-melt adhesives for packaging and footwear
- Electronics & Electrical:
- Protective casings for devices
- Wire and cable insulation
AdvantagesHigh Elasticity and Flexibility – Provides rubber-like stretch and softness Good Impact and Tensile Strength – Enhances durability and wear resistance Thermoplastic Nature – Can be easily melted, reshaped, and recycled Soft-Touch Feel – Ideal for ergonomic grips and overmolding Good Adhesion to Various Materials – Suitable for multi-material applications Resistant to Oils, Greases, and Chemicals – Performs well in harsh environments Lightweight – Reduces material costs and improves energy efficiency Good Weather and UV Resistance – Certain formulations (e.g., SEBS) have enhanced outdoor durability Easy Processing – Compatible with injection molding, extrusion, and blow molding
DisadvantagesLower Heat Resistance – Limited performance above 100°C Lower Stiffness Compared to Some Plastics – May require reinforcement for structural applications Can Become Sticky in Hot Conditions – Some grades may soften and lose shape retention Higher Cost Than Standard Plastics – More expensive than traditional polyolefins like PP and PE Limited Load-Bearing Capacity – Not suitable for heavy-duty mechanical applications
TetrafluoroEthylene/perfluoroPropylene copolymers (FEP)
Tetrafluoroethylene/Perfluoropropylene (FEP) is a melt-processable fluoropolymer composed of tetrafluoroethylene (TFE) and hexafluoropropylene (HFP). It belongs to the family of fluoropolymers and shares many properties with polytetrafluoroethylene (PTFE), but with enhanced processability due to the incorporation of HFP.
StructureThe structure of Tetrafluoroethylene/Perfluoropropylene (FEP) copolymer consists of a randomly distributed backbone of tetrafluoroethylene (TFE) and hexafluoropropylene (HFP) monomer units. The TFE units provide the high thermal and chemical resistance characteristic of fluoropolymers, while the HFP units introduce branching that disrupts crystallinity, enhancing flexibility and melt processability. The polymer chain is composed of repeating –CF₂–CF₂– segments from TFE and –CF₂–CF(CF₃)– segments from HFP, where the bulky trifluoromethyl (-CF₃) groups reduce intermolecular forces, lowering the melting point compared to PTFE. This molecular architecture results in a copolymer with excellent non-stick properties, chemical inertness, and transparency while being more easily processed using conventional melt-processing techniques.
PropertiesTetrafluoroethylene/Perfluoropropylene (FEP) copolymers exhibit a unique combination of thermal stability, chemical resistance, electrical insulation, and mechanical flexibility. They can withstand continuous exposure to high temperatures up to 200°C (392°F) while maintaining their structural integrity. FEP is highly resistant to a wide range of chemicals, including acids, bases, and organic solvents, making it ideal for harsh environments. Its non-stick and low-friction surface prevents adhesion and contamination, similar to PTFE. Unlike PTFE, FEP is melt-processable, allowing for fabrication through extrusion, injection molding, and blow molding. It also possesses excellent electrical insulating properties, with a low dielectric constant and high breakdown voltage, making it a preferred choice for wire and cable insulation. Additionally, FEP is optically transparent, resistant to UV radiation, and does not degrade under prolonged exposure to environmental factors, further enhancing its suitability for industrial, aerospace, and medical applications.
Applications of FEP Copolymers:
- Wire & Cable Insulation: Used in aerospace, automotive, and telecommunications due to high heat and chemical resistance.
- Chemical Processing Equipment: Linings for pipes, valves, and tanks in harsh chemical environments.
- Medical Tubing & Catheters: Biocompatible and resistant to sterilization processes.
- Food & Beverage Industry: Non-stick coatings for cooking equipment and food processing machinery.
- Semiconductor Industry: Used in chip manufacturing equipment due to high purity and chemical resistance.
- Heat Shrink Tubing: Provides electrical insulation and protection in extreme environments.
- Optical Fiber Coatings: Protects fibers in harsh conditions without affecting signal transmission.
- Laboratory Equipment: Used for beakers, flasks, and other chemical-resistant lab tools.
Advantages of FEP Copolymers:
- Excellent Chemical Resistance: Inert to most acids, bases, and solvents.
- High Thermal Stability: Can withstand temperatures up to ~200°C (392°F).
- Non-Stick Properties: Similar to PTFE (Teflon), preventing adhesion of substances.
- Low Friction: Reduces wear in moving parts and improves efficiency.
- Electrical Insulation: High dielectric strength makes it ideal for electrical applications.
- Transparent & UV Resistant: Can be used in optical and outdoor applications.
- Biocompatibility: Safe for medical and food-contact applications.
Disadvantages of FEP Copolymers:
- Lower Mechanical Strength: Weaker than PTFE in terms of tensile strength and wear resistance.
- Higher Cost: More expensive than common plastics like PVC or polyethylene.
- Limited Temperature Resistance: Slightly lower thermal stability than PTFE.
- Difficult Processing: Requires specialized molding and extrusion techniques.
- Fluorine Emission on Decomposition: Can release toxic fumes if overheated beyond its thermal limits.
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