Maya Ellison
Plastic is a versatile material used in a wide range of products, from televisions and cars to clothing and medical tubing. While no plastic is truly unbreakable, certain types of plastic are highly durable and impact-resistant. To manufacture these tough plastics, various processes are employed, including the use of different raw materials, refining processes, and compounding methods. The choice of raw materials is crucial, with most plastics today derived from crude oil due to its accessibility and ease of processing. However, there is a growing trend towards using renewable sources such as biomass or animal waste to create more sustainable bioplastics. The refining process involves heating crude oil to separate it into lighter fractions, with naphtha being a key compound for plastic production. Polymerisation then converts these fractions into higher molecular weight hydrocarbons, forming long chains of chemically bonded monomers. Compounding involves melt-blending different materials to create unique formulations, which are then transformed into finished products through extrusion or moulding processes. While the technology for creating stronger plastics exists, consumer demand for better environmental protection is needed to drive the development and use of these materials.
| Characteristics | Values |
|---|---|
| Toughest unreinforced plastics | ABS, polycarbonate, acrylic |
| Strongest economic plastics | 30% glass-filled compounds of ABS or nylon |
| Extreme strength | 63% glass-filled epoxy sheet molding compound (Quantum Lytex) |
| Strongest and stiffest injection moldable plastics | Kyron MAX compounds by Piper Plastics |
| Plastic characteristics | Light, durable, easily formable, deformable |
| Plastic manufacturing | Small industrial operations |
| Plastic sources | Crude oil, natural gas, coal, renewable biomass, animal waste |
| Plastic types | PET, PVC, ABS, polyethylene, polycarbonate, acrylic |
| Plastic properties | Shatter-resistant, abrasion-resistant, bullet-resistant, UV-tolerant, anti-static, recyclable, rigid, flexible |
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What You'll Learn
Use of renewable resources
The vast majority of plastic today is derived from crude oil and natural gas, which are non-renewable resources. However, the limited nature of these oil reserves is driving a need for newer plastics from renewable resources.
Bioplastics are plastic materials produced from renewable biomass sources. They are made from natural biopolymers, including polysaccharides (e.g. corn starch, rice starch, cellulose, chitosan, and alginate) and proteins (e.g. soy protein, gluten, and gelatin). They can also be made through the chemical synthesis of sugar derivatives (e.g. lactic acid) and lipids (vegetable fats and oils) from plants and animals.
Bioplastics are a more sustainable alternative to conventional plastic production, as they significantly reduce greenhouse gas emissions and decrease non-renewable energy consumption. They are also compatible with existing recycling streams and can be biodegraded in controlled or predictable environments.
However, bioplastics are not automatically a more sustainable alternative. They can have negative agricultural impacts, compete with food production, have unclear end-of-life management, and be more costly. Additionally, bioplastics can increase eutrophication and acidification, which can be harmful to water resources and aquatic animals.
To manufacture unbreakable plastic using renewable resources, one could potentially employ the use of bioplastics. However, it is important to consider the specific type of bioplastic, its end-use, and the environmental implications to determine the most sustainable option.
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Polymerisation
Plastics are polymers, which are large molecules formed by covalently joining many monomer units together in the form of chains. Polymerisation is the process of linking hydrocarbon monomers together by a chemical polymerisation mechanism to produce polymers. This process generates thick, viscous substances known as resins, which are used to make plastic products.
An example of the polymerisation process is the case of the ethylene monomer. Ethylene is a gaseous hydrocarbon. When subjected to heat, pressure, and a catalyst, it joins together into long, repeating carbon chains. These joined molecules, or polymers, form a plastic resin known as polyethylene (PE). Polyethylene is processed in a factory to make plastic pellets, which are then poured into a reactor, melted into a thick liquid, and cast into a mould. The liquid then cools and hardens into a solid plastic product.
There are two types of polymerisation: addition polymerisation and condensation polymerisation. In addition polymerisation, one monomer connects to another to form a chain of monomers. This process requires a catalyst, typically a peroxide. Common examples of addition polymers include polyethylene, polystyrene, and polyvinyl chloride. In condensation polymerisation, two or more different monomers are joined by the removal of small molecules such as water. This process also requires a catalyst for the reaction to occur between adjacent monomers. Common examples of condensation polymers include polyester and nylon.
Some durable plastics with high impact resistance include polycarbonate (PC), acrylonitrile butadiene styrene (ABS), and polyamide-imide (PAI). These plastics are used in various applications where impact resistance and durability are required, such as safety equipment, containers, and outdoor furniture.
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Compounding
Plastic compounding is a process that involves blending raw plastic material with additives to achieve desired characteristics such as colour, properties, and performance requirements. This process allows for the customisation of plastic to meet specific needs, making it more effective, efficient, and uniform.
The compounding process typically begins with selecting the appropriate base feedstock that suits the desired application. This feedstock is then tested to ensure that it meets the required specifications. Once the feedstock is approved, the prework and formulation begin to create the masterbatch. This stage involves determining the additives ratio and using salt-and-pepper blends to achieve the desired properties and colour.
The next step in the compounding process is melt-blending, where the plastic is combined with specific additives that modify its thermal, physical, aesthetic, and electrical characteristics. This can include the use of anti-abrasion additives, antioxidants, UV stabilizers, and other value-adding agents. The screw and barrel design play a crucial role in this stage, as the screw transports the resins towards the die, and the barrel can be heated to different temperatures depending on the resin's properties.
After melt-blending, the material is pelletized, where it is processed into a plastic part through moulding or extrusion. The extrudate, which resembles long plastic strands, is then cooled in a water bath or by spraying as it moves on a conveyor belt towards the granulator. The pelletized material is then tested again to ensure that it meets the desired specifications. If any issues are found, adjustments can be made to the formula, such as changing the speed of the screws, temperature of the extruder, or correcting the base resin ratio.
Finally, the compounded plastic is ready for final pellet cutting and packaging. The compounded plastic can now be used to create various products, such as impact-resistant materials, automotive components, or consumer goods.
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Impact-resistant plastics
While nothing is truly "unbreakable", some plastics are tougher and more impact-resistant than others. The toughness of a material is determined by its ability to withstand high-impact forces without breaking, fracturing, or deforming. Tough materials are strong and ductile, allowing them to bear heavy loads of force and stretch under pressure.
The impact resistance of a plastic material is often tested using the Notched IZOD impact test, which measures the energy absorbed by a plastic to determine how much force it can withstand before deformation. The Gardner test is another method, which involves dropping a weight straight down onto a rounded object sitting on the material being tested.
Some of the toughest, most impact-resistant plastics include:
- Polycarbonate (PC): This plastic is incredibly tough and can be made transparent, like glass. It is highly resistant to heat, flame, and UV light when properly treated, making it ideal for safety glasses, riot shields, and headlight bezels. However, it is not very scratch-resistant and is one of the more expensive engineering polymers.
- ABS: This plastic is known for its high impact resistance and mid-range cost, making it a popular choice for various manufacturing industries. ABS is easy to machine and bonds well with adhesives, paint, and coatings. It is commonly used in car bumpers, instrument panels, luggage, and even children's toys.
- High-Density Polyethylene (HDPE): HDPE is a durable and versatile thermoplastic with excellent impact resistance and tensile strength. Its molecules are tightly packed, making it incredibly tough and rigid. It is also resistant to chemicals, corrosion, absorption, and abrasion. However, it only offers low-to-moderate heat resistance and is susceptible to stress cracking under extreme pressures.
- Polyamide-imide (PAI): PAI is an extremely tough, strong, and stiff plastic with good chemical resistance, electrical grade insulation, and low thermal expansion. It boasts tensile and compressive strength, allowing it to stretch and compress to adjust for high impacts.
- Polyetheretherketone (PEEK): This plastic can withstand impact at almost any temperature.
It is important to note that the impact resistance of plastics is temperature-dependent, with plastics generally becoming more brittle at cooler temperatures and tougher at warmer temperatures. Prolonged exposure to elevated temperatures and UV light can decrease a plastic's toughness over time. Additionally, the shape and geometry of plastic parts can affect their impact resistance, with sharp internal corners being more prone to breakage than rounded corners.
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Surface coatings
While no solid material is truly unbreakable, surface coatings can enhance the durability of plastics. Polycarbonate, for instance, is highly impact-resistant but prone to scratching and yellowing without a surface coating. Coatings are applied to polycarbonate sheets to prevent scratching and protect against yellowing.
One such coating is Plexiglas®, an acrylic plastic polymethylmethacrylate (PMMA) that is 30 times stronger than ordinary glass. However, Plexiglas® is sensitive to scratches and solvents, and it will burn. Other acrylic plastics, such as Bonoplex, Perspex, and Plexiglas, are also sensitive to acids, acetone, and other solvents and will burn.
Optiguard™ Hard Coatings is another surface coating that uses UV curing solvent-based Polyacrylate with a cured film thickness of 2–25 microns. The UV output triggers a cross-linking process, resulting in high abrasion and chemical resistance with excellent adhesion to various substrates. Optiguard™ is used in demanding environments, including military, automotive, aerospace, and marine applications.
Additionally, Optiguard™ offers a range of coatings, including Anti-Fog, a primer-less, non-marring coating that eliminates fogging, misting, or water droplets on polycarbonate and other plastic substrates. It also provides a high-performance hygiene coating that combines chemical and abrasion resistance with easy-to-clean, hydrophobic, and anti-microbial properties.
While these surface coatings enhance the durability of plastics, it's important to note that even the toughest unreinforced plastics, like ABS and polycarbonate, are not truly unbreakable.
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Frequently asked questions
Technically, nothing is unbreakable, but you can make plastic that is extremely durable and impact-resistant. Polycarbonate is a popular choice for manufacturing such plastic. It is 250 times stronger than glass and 30 times stronger than acrylic. It is also easily worked, moulded, and thermo-formed or cold-formed.
Other materials that can be used to make unbreakable plastic include ABS, which is robust, flexible, glossy, highly processable, and impact-resistant, and Tritan, which is a BPA-free alternative to polycarbonate.
The process of making plastic involves the extraction of raw materials, largely crude oil and natural gas, but also coal. These materials are then refined and transformed into different petroleum products, including monomers, which are the basic building blocks of polymers. The monomers are then polymerized, or chemically bonded into chains. Finally, the plastic is formed into its final shape through extrusion or a moulding process.
Some common types of plastic include polyethylene, PVC, PET, and ABS.
Plastic is lightweight, durable, and easily formable into products. It is also usually stronger than glass and can be made to be shatter-resistant.
