Alexei Volkov
Plastic polymers are known for being lightweight materials, but their weight can vary depending on their category. To determine whether a plastic polymer is lightweight, its volumetric density mass should be considered. Generally, plastic polymers are lighter than traditional materials such as metal, glass, concrete, and wood. For example, Teflon®, one of the heaviest plastic polymers, has a volumetric mass density of 540 kg/m3, which is much lower than that of aluminum. MIT researchers have recently developed a new polymer that is two times stronger than steel with just one-sixth of the material bulk. This polymer can be mass-produced and used as a coating for cars, phones, or building material for bridges. Other lightweight plastic polymers include polyoxymethylene, polyimide, polyphenylene sulfide, and polyetheretherketone.
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What You'll Learn
- Polyoxymethylene, or engineering steel, has exceptional strength and rigidity
- Polyetheretherketone, or PEEK, is used in aerospace, medical devices, and electronics
- Polyimide can withstand temperatures above 400°C and is stable in extreme environments
- Polyphenylene sulfide, or PPS, has high heat resistance and is used in aerospace and electronics
- Acrylic is 17 times more impact-resistant than glass and can replace it in many applications
Polyoxymethylene, or engineering steel, has exceptional strength and rigidity
Polyoxymethylene, also known as engineering steel, is a lightweight plastic polymer with exceptional strength and rigidity. It is often used as a direct replacement for metals due to its stiffness, dimensional stability, and corrosion resistance.
Polyoxymethylene (POM) is an engineering thermoplastic used in precision parts that require high stiffness, low friction, and excellent dimensional stability. It is characterized by its high strength, hardness, and rigidity, even at temperatures as low as −40 °C. POM has a density of 1.410–1.420 g/cm3, making it relatively lightweight compared to other plastics.
POM is commonly used in various industrial sectors, including mechanical, automotive, electrical, construction, and biomedical. For instance, it is used to manufacture gears, sliders, and other mechanical transmission parts due to its excellent wear resistance and good self-lubrication. POM can also be reinforced with fibers such as glass, carbon, or stainless steel to increase its strength and improve its mechanical properties.
The discovery of Polyoxymethylene is credited to German chemist Hermann Staudinger, who studied the polymerization and structure of POM in the 1920s. However, due to issues with thermal stability, it was not commercialized until the 1950s when researchers at DuPont synthesized a stable version. Today, POM is widely used and has become crucial for many industries due to its unique combination of strength, rigidity, and lightweight properties.
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Polyetheretherketone, or PEEK, is used in aerospace, medical devices, and electronics
Polyetheretherketone, often abbreviated as PEEK, is a high-heat polymer with excellent mechanical, thermal, and chemical properties. PEEK is a semi-crystalline thermoplastic polymer that was commercialised in the early 1980s and later proposed for medical applications. It is known for its high strength and stability in harsh chemical and high-temperature environments, making it suitable for various industries, including aerospace, medical devices, and electronics.
In aerospace, PEEK is used for manufacturing aircraft parts, such as critical engine parts and exterior components. Its high-temperature performance, tribological interaction of dry and lubricated material contacts, and excellent resistance to rain erosion make it an ideal choice. Additionally, its inherent flame retardancy and low smoke and toxic gas emission reduce hazards in the event of a fire.
In the medical field, PEEK is used for medical implants, such as artificial joints, dental instruments, and neurosurgical applications. It offers improved biocompatibility for load-bearing implants and can be used as an alternative to titanium and titanium alloy implants, which can cause bone loss and implant failure. PEEK is also used in spinal fusion devices and reinforcing rods, as its stiffness is similar to bone, allowing for uniform healing.
PEEK is also used in electronics applications, providing parts with long-term operating reliability over fluctuating ranges of temperature, pressure, and frequency. Its inherent purity and excellent mechanical and chemical stability minimise contamination and maximise safety during the handling of silicon wafers. PEEK is further utilised in electrical cable insulation and the packaging of electronic components.
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Polyimide can withstand temperatures above 400°C and is stable in extreme environments
Polyimide is a polymer compound with an imide ring bond in its molecular chain. It is a class of polymers consisting of aromatic rings coupled by imide linkages, which are formed by two carbonyl groups attached to the same nitrogen atom. Polyimides are typically synthesized by the reaction between a dianhydride and a diamine or, less frequently, between a dianhydride and a diisocyanate. Both processes are referred to as imidization.
Polyimide exhibits extraordinary performance, with high strength and the ability to withstand temperatures above 400°C. Its stabilized physical properties range from 196°C to 300°C, and it demonstrates extreme heat resistance, robust mechanical properties, excellent dielectric properties, and chemical resistance. This makes polyimide ideal for use in extreme environments.
The high glass transition temperature (Tg) of thermosetting polyimide makes it suitable for coatings and film substrates. Thermoplastic polyimides, on the other hand, have a Tg between 200°C and 300°C. They can be easily moulded into different shapes, making them versatile for machinery parts in various industries.
Polyimide's electrical properties remain consistent from cryogenic to high temperatures, and it exhibits minimal thermal expansion due to its low coefficient of thermal expansion. This gives it high dimensional stability. Additionally, it offers excellent flame resistance and is less flammable than other polymer resins.
Polyimide is widely used in electronic devices, flexible printed circuits (FPCs), smartphones, automobiles, motor coils, wire coating, and dielectric/passivation layers for semiconductors. In the aerospace industry, its high heat resistance and electrical insulation properties are advantageous for protective films for critical satellite devices.
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Polyphenylene sulfide, or PPS, has high heat resistance and is used in aerospace and electronics
Polyphenylene sulfide (PPS) is a semi-crystalline engineering thermoplastic that offers excellent mechanical and thermal properties. PPS has a unique molecular structure, which gives it its distinctive characteristics. It is a polymer made from monomers called phenylenes and sulfides, which are linked in aromatic rings.
PPS is known for its high strength and rigidity, making it ideal for applications that require structural integrity. It also has a high modulus of elasticity, enabling it to resist deformation under stress. This, coupled with its good fatigue resistance, makes PPS a popular choice for structural components in the aerospace industry, such as spars, ribs, and bulkheads.
One of PPS's standout features is its high heat resistance. It can withstand temperatures up to 240°C (464°F) continuously and even up to 260°C (500°F) for short periods. This heat resistance, combined with its excellent electrical insulation properties, makes PPS highly valued in the electronics industry. PPS is used in the production of connectors, switches, circuit boards, and other electronic components that require high-temperature resistance and good electrical insulation.
In addition to its heat resistance, PPS is also inherently flame-resistant. This characteristic, along with its high strength, makes PPS a versatile material for demanding applications in diverse industries, including aerospace and electronics.
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Acrylic is 17 times more impact-resistant than glass and can replace it in many applications
Acrylic is a transparent and solid thermoplastic homopolymer made from polymer and carbon. It is also known as plexiglass or polymethyl methacrylate (PMMA). Acrylic is 17 times more impact-resistant than glass, making it a suitable replacement for glass in many applications.
Acrylic's impact resistance makes it a safer alternative to glass, especially in applications where security and protection are priorities. Acrylic is also half the weight of glass, making it ideal for projects where weight is a crucial factor in designing. For example, in caravans, boat windows, and aquariums, acrylic sheets can be used instead of glass to reduce weight without compromising on transparency.
Acrylic's lightweight property also makes it a cost-effective material, as it reduces transportation costs. Additionally, acrylic is easier to work with than glass. It can be heated, moulded, and bent into various shapes, including curved forms, without compromising its excellent optical properties. On the other hand, bending and shaping glass into complex forms can be challenging due to its limited durability and the difficulty in achieving a smooth finish.
Acrylic is also more scratch-resistant than glass, depending on the manufacturing process. It is less prone to scratching and shattering, making it ideal for everyday applications such as eyeglass lenses. Acrylic is also easier to maintain and clean than glass. Glass tends to collect dirt quickly and is not easy to wash, whereas acrylic sheets can be maintained with standard cleaning solutions.
However, it is important to note that acrylic has its limitations. While it is more impact-resistant than glass, it is also easier to crack, especially when exposed to certain cleaning solvents. Acrylic also has a high gloss finish, making it ideal for display cases, but it may not be suitable for applications requiring a matte or non-reflective surface. Additionally, in very special uses, such as experimental apparatus or high-temperature applications, acrylic cannot replace glass.
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Frequently asked questions
The world of polymers and plastics is ever-evolving, with new innovations being made regularly. One of the lightest plastic polymers developed so far is a two-dimensional polymer created by MIT chemical engineers. It is stronger than steel and as light as plastic.
This polymer can be used as a lightweight, durable coating for car parts, cell phones, or even as a building material for bridges.
Other lightweight plastic polymers include polyoxymethylene (POM), polyetheretherketone (PEEK), polyimide, polyphenylene sulfide (PPS), and polycarbonate.
Plastic polymers are generally much lighter than traditional materials such as metals, glass, concrete, and wood. For example, Teflon, one of the heaviest plastic materials, has a volumetric mass density of 540 kg/m3, while aluminum has a density of 2,700 kg/m3.
