3.042 Materials Project Laboratory
Design Review
Team No-Drip
Tania Chan
Michele Dufalla
Jacqueline Greene
3.042 Materials Project Laboratory
Design Review
Team No-Drip
Tania Chan
Michele Dufalla
Jacqueline Greene
New Goal
+
http://www1.istockphoto.com/file_thumbview_approve/1168596/2/istockphoto_116859
6_plastic_can_container.jpg, http://www.baproducts.com/spigot.jpg
Plastic Joining
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Fasteners
Hinges
Hot Die
Fusion and Hot Wire/Resistance Welding
Hot Gas Welding
Induction/Electromagnetic Welding
Press Fits/Shrink Fits
Snap Fits
Spin Welding
Staking/Cold Forming
Threads
Ultrasonic Welding
Vibration Welding
Lasers
Adhesives
Solvents
**List from Joining of Plastics by Jordan Rotheiser (2nd ed.)
Plastic Joining
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Fasteners
Hinges
Hot Die
Fusion and Hot Wire/Resistance Welding
Hot Gas Welding
Induction/Electromagnetic Welding
Press Fits/Shrink Fits
Snap Fits
Spin Welding
Staking/Cold Forming
Threads
Ultrasonic Welding
Vibration Welding
Lasers
Adhesives
Solvents
**List from Joining of Plastics by Jordan Rotheiser (2nd ed.)
Hot Plate Welding
(from Joining of Plastics by Jordan Rotheiser (2nd ed.)
HDPE vs. LDPE
• Max Temp =
120°C
• Melt Temp =
130°C
• Max Temp =
80°C
• Melt Temp =
120°C
http://www.dynalabcorp.com/technical_info_hd_polyethylene.asp
http://www.dynalabcorp.com/technical_info_ld_polyethylene.asp
Method
http://www.cooking.com/images/products/shprodde/743196.jpg,
http://www.flagstaff.az.gov/images/pages/SC581/plastic%20bag.JPG
Extrusion
http://www.flagstaff.az.gov/images/pages/SC581/plastic%20bag.JPG
http://www.midi-classics.com/i/p19228.gif
Sample prep
• Plastic (HDPE, LDPE) was cut in 1x6 in
strips
• Samples were welded together with a
clothes iron, pressed together and allowed
to cool at room temperature
• Last week tested initial control samples of
varying thicknesses, as well as ability of
LDPE to bond with HDPE.
90º Peel Test
INSTRON
1/16” LDPE
3x1 in contact area
1 in wide
1/8” HDPE
Free-moving stage
Shear Test
1/8” HDPE
4 layers of
clear LDPE
film
(0.0006”)
1/8” HDPE
3x1 in contact
area
Results of Peel Test
• 1/16 in LDPE was non-uniformly bonded
to the 1/8 HDPE (due to greater thickness,
more difficult to melt with iron)
• Maximum Load: 0.020 kN
• Could not test LDPE film:1/8 HDPE
because strength of adhesion > than the
tensile strength of LDPE which is 1700psi
(22kN, http://www.mcmaster.com/)
Results of Shear Test
• The bond between the LDPE film and the
1/8 HDPE was greater than the tensile
strength of the 1/8 HDPE! (4400psi / 30
MPa/ 58 kN, www.mcmaster.com). We
could tell because the HDPE started
necking rather than breaking the adhesive
bond
• Max load = 2.070 kN, Stress at Peak 55
MPa
Shear Force 1/8 HDPE: LDPE film
necking
Immediate Next Steps…
• Continue 90o Peel Test and Shear Test
3 Sets of Control Samples:
1/8” HDPE Substrate
-White LDPE Film
1/16” HDPE Substrate
1/8” LDPE Substrate
-White LDPE Film
-Black LDPE Film
-White LDPE Film
-Black LDPE Film
-1/16” LDPE Sheet
-Black LDPE Film
-1/16” LDPE Sheet
-1/16” HDPE Sheet
-1/16” LDPE Sheet
-1/16” HDPE Sheet
Goals of the Materials Testing
Control Samples are Pure Polyethylene
-no contaminations, impurities
-effects of thickness, colors, processing temperature and
material density on polyethylene adhesion
Materials Testing Using Post-Consumer Polyethylene
-ink, dye, processing agents
-nonuniform density
Ultimate Goal
-Establish a range of temperature, pressure, time and
processing condition optimal for polyethylene welding
Design of the Tap
Basic Pop Rivet Design to Attach
Pinch Tube at the Lid of Jerrycans
Design Considerations:
– Simple design, reduce
production and materials
costs
Materials Considerations:
– Tube to be made from
recycled polyethylene
– Sealing between the
flange and the containers
surface
Tube Production
Continue with the idea of post-consumer
polyethylene recycling
– Melt plastic bags and extrude melt into tubes
– Questions to be answered:
• Is the process plausible?
• How durable is the resultant products?
• Can the procedure be done in the field?
Tap Production and Plastic Welding
• Plastic Welding Will Be Used to Attach Tap onto Jerrycans
Lids
• Using the welding parameters (temperature, time and
processing conditions) to attach tube to containers
• Challenges:
– Tricky interface between tube and containers, how to apply
plastic welding?
– Is plastic welding a water proof seal?
– Can plastic welding withstand the chlorination in the water?
Revised Gantt Chart
2/6/07
2/16/07
2/26/07
3/8/07
3/18/07
3/28/07
4/7/07
4/17/07
4/27/07
5/7/07
5/17/07
Background Research
Recycling
Processing Cost
Material Cost
Target User
Materials Economic Analysis
Polyethylene Properties Research
Polyethylene Recycling Research
Plastic Welding Testings
90 Degree Peel Tests
Shear Tests
Production of Prototype #1
Extrusion of Plastic Tubes from Recycled Polyethylene
Design of Prototype #1 on SolidWorks
Designing Interface betw een Tab and Containers
Testing Plastic Welding Adhesion between Tab and Container
Production of Final Product
Increase Efficiency and Decrease Cost of Production
Troubleshoot Defects in Final Product
Preparation for Final Presentation
Completed
Remaining