Poly Phenylene Oxide (PPO)

Manufacturing aspects of PPO

Poly-(phenylene oxide) is known as poly (2,6-dimethyl-p-

phenylene ether). The most successful method of preparation involves
oxidative coupling of 2, 6 dimethyl phenol. The reaction is carried out at 28-
46°C by bubbling oxygen through a solution of the phenol in the presence
of a copper (I) salt-amine complex for about 7 minutes. The reaction
mixture is added to methanol filtered and washed with methanol to give a
colourless polymer.
 Properties of PPO

The rigid structure of the polymer molecules leads to

a material of a high Tg of 208°C. There is a also a secondary
transition at 116°C and the small molecular motions that this
facilitates at room temperature give the polymer in the mass
a reasonable degree of toughness.
 Properties of PPO

When polymerized the polymer is crystalline but has

a surprisingly low reported melting point (Tm) 257°C. The
ratio of Tg & Tm of 0.91 (in terms of K) is uniquely high.
Because of the small differences in Tg and Tm there is little
time for crystallization to occur on cooling from the melt and
processed polymer is usually amorphous. However, if
molecular movements are facilitated by raising the
temperature or by the presence of solvent crystallization can
occur.
 Properties of PPO

The polymer is dissolved by halogenated and

aromatic hydrocarbons of similar solubility parameter. Stress
cracking can occur with some liquids.

Being only lightly polar and well below the Tg at

common ambient temperature the polymer is an excellent
electrical insulator even at high frequencies. The polymer
exhibit very good hydrolytic stability.
 Properties of PPO

One particular feature of PPO is its exceptional

dimensional stability amongst the so-called engineering
plastics. It has a low co-efficient of thermal expansion, low
molding shrinkage and low water absorption thus enabling
molding to close tolerances. It is more or less self-
extinguishing polymer with a good chemical resistance
properties.
 Properties of PPO

Properties Units Values

Specific gravity ---- 1.5 – 1.10
Tensile strength MPa 41-110
Tensile modulus MPa 234-276
Flexural modulus Mpa 221-276
Elongation at break % 2-3
Impact strength izod, Notched, J/m 107-537
Hardness R 115-120
Deflection temperature under load 0
C 82-149
(1.82 Mpa)
Vicat softening point °C 250-310
Coefficient of linear expansion mm/mm/0C 6-14 x 10-5
Water absorption, 24hrs % 0.06-0.12
Dielectric strength KV/mm 15.7-27-6
Dielectric constant 10-6 Hz 2.7-2.9 Power
factor 0.0001-0.0025
Glass transition temperature °C 100-150
 Characteristics of PPO

Possesses high melting point and glass transition temperature

Low co-efficient of thermal expansion
Continuos use temperature upto 100°C
Excellent electrical properties
Low loss factor
Dissipation factor is quite low
Very good dimensional stability
High heat distortion temperature (179°C)
Low moulding shrinkage
Low warpage
Good impact resistance
Low water absorption
Soluble only in halogenated and aromatic hydrocarbons
Excellent flame retardancy
Outstanding hydrolytic stability
 Characteristics of PPO

•Since PPO has a high heat deflection temperature it is not

surprising that high processing temperatures are necessary.

•Typical cylinder temperatures are about 280-330°C and

mold temperatures 100 – 250°C.

•If overheated, the material oxidizes resulting in poor finish

and streakiness. Because of this it is advisable to purge
machines before they are cooled down after molding.

•The melt of PPO are almost Newtonian viscosity being

almost independent of shear rate.
 Characteristics of PPO

Due to their extremely low moisture absorption

PPO resin can be molded without the need of drying.
Surface defect in case of due to the trapped moisture, can
be avoided by proper drying.

Drying is recommended in instances, where

appearance of parts are necessary or when some type of
secondary finishing is to be done, such as painting or hot
stamping. Drying temperature vary with the resin grades.
Temperature of 93 – 102°C for 2-4 hours are
recommended for drying.
 Characteristics of PPO

They are available in the following grades.

•Glass reinforced
•Graphite filled
•Foam grade
•Plating and suffering grade
•High modulus grade
•Blow moulding grade
•Injection moulding grade
 Characteristics of PPO

They can be processed by the following processing

techniques.

•Extrusion
•Foam moulding
•Thermoforming
 Serviceability
•The mechanical properties of PPO are generally good with high stiffness and
low creep over a good temperature range.

•Good toughness extends to low temperature.

•Excellent dimensional stability is associated with the non crystalline

structure a low co-efficient of thermal expansion and very low moisture
absorption electrical properties are generally good and unaffected by
moisture.

•Dielectric properties in particular are good and stable.

•It is classified as self extinguishing and non-dripping.

•Hydrolytic stability is exceptionally high it is also highly resistant to water,

including hot water and steam. It can be repeatedly sterilized in steam
autoclaves.
 Applications of PPO

•Automotive
•Electricals / Electronics
•Miscellaneous
 Applications of PPO

Automotive:

Instrument panels, steering column, cladding,

central consoles, loud speaker housings ventilator grills,
nozzles, parcel shelves, radiator tanks, cable connectors,
bulb sockets, air inlet and outlet grills and outer mirror
housings.
 Applications of PPO
Electricals/Electronics:
Television tuner strips, microwave insulation component,
transformer housings. Computer terminals, printers, modems,
typewriter bases, video games, copier, capacitor casings, outlet
boxes, coil bobbins, smoke detectors, intrusion alarm, motor
covers and switches.

Fig. 33. Capacitor casing

 Applications of PPO
Miscellaneous:
Water pumps, water meters, sprinkler systems, hot water
tank, washing machine parts, welder’s protective visors, tennis
racquets, textile components and valves for drink vending
machines.

Fig. 34. Welder’s protective visor Fig. 35. Washing machine parts
 Blends & Alloys of Engineering
Thermoplastics

Blends and alloys of engineering plastics is

made mainly because of gaining extra performance of
the plastics.
 Blends of Nylon

•These compatiblized blends are formulated for injection

molding, extrusion, and thermoforming , but they can be
used for blow and compression molding . The blends show
good processibility and flow high heat and chemical
resistance , oil , wear and abrasion resistance , dimension
stability , low temperature impact strength and reduced
moisture sensitivity.

•These blends find use in automotive ,chemicals, electricals ,

anti-vibration mount and sports industry.
 Blends of Nylon

Blends of Nylon 66
The alloys of polyamide (Nylon 66 , and PPO ) are used as a
commercial products because higher HDT and reduced sensitivity to
moisture . Toughness are used to reduce brittleness of these blends.

Blends of Nylons 6 and Blends of 66

In compatible hydrocarbon polymers such as PE can be melt with
nylons to yield compositions that have improved higher permeability and
are processable film and filaments and bottles. Improvement in moisture
absorption, impact strength , flexibility, moulding characteristics and
structure uniformity are claimed for blends made from nylon and ethylene
/ alkyl acrylate ester copolymers.
 Blends of PET
PET/PC
Partially miscible blends (miscibility is controlled by the level of
transesterification) with co-continuous morphology show improved
processability, chemical resistance, crystallinity, elongation, low
temperature impact and tensile strength. Blends also show decreased
shrinkage and high heat deflection temperature. These blends are
especially interesting for reinforced products because the warpage is
significantly decreased.

PET/Elastomers
These blends are formulated for extrusion, injection,
compression, blow and transfer molding. The blends contain up to 35 wt.
of glass fiber. They show good processability rigidity impact and tensile
strength as well as excellent weatherability.
 Blends of PBT

PBT / PET
The injection molding of glass fiber reinforced PBT leads to long
directional orientation and anisotropy in the molded part. And additional
deficiencies is the poor surface quality of the molded parts . But when
blended with PET warpage of the part is clearly diminished and surface
quality improved. The blends also show improvements in heat deflection
temperature and impact strength.

PBT / Elastomers
The blends developed for molding show good heat deflection
temperature processability, electrical properties stiffness, strength,
dimensional stability impact strength, solvent and chemical resistance.
 Blends of PBT

PBT/ABS (contain upto 30% glass fiber)

The blend shows excellent processability, high

gloss, stiffness at high temperature and mechanical
strength, heat deflection temperature, low shrinkage, good
dimensional stability, impact strength as well as solvent
and chemical resistance.
 Alloys of Polycarbonate

PC-ABS
Alloys of a Bisphenol A poly carbonates with ABS and MBS resins
have been known for many years. These alloys retain their impact strength
down to -50 C .They are non-splintering . The hardness of the alloys is
comparable to that of PC. Because of the above properties, ability to mould
to close dimensional tolerances , low warpage , low shrinkage, surface finish,
PC-ABS alloys are widely used in automotive industry for electrical
application and for housings of domestics and business equipments.

PC-PBT
This is particularly notable for its high levels of toughens and
resistance to petrols and oils.

PC-PET
This is recently introduced for incoporating advantages of both resin
in the alloys
 Blends of polyacetal

•Although unmodified polyacetals already have high

inherent toughness they exhibit a certain notch sensitivity.

•That is by virtue of the stress concentration that arises,

sharp notches effect a substantial drop in impact strength.

•Blending polyacetal with elastomer brings a noticeable

improvement not only in the notched impact strength, but
also in the ability to bear multiaxial impact loading.
 Blends of Polyacetal

Polyacetal / TPU
•Among the elastomers, thermoplastic polyurethane have the greatest
significance for the impact modification of polyacetals.

•Such blends are formulated for extrusion, injection, blow,

compression and transfer moulding.

•They show excellent processability, rigidity high impact strength,

high fatigue, flexural and tensile strength, low water absorbency and
resistance to chemicals.

•Mostly contain 10-30 wt of TPU, and have co continuous morphology

for especially good performance.
 Blends of Polyacetal

Polyacetal / Butadiene

Elastomers based on polybutadiene or poly acrylates are

important modifiers. The essential advantage of
modification with poly butadiene is better cold impact
strength.
 Blends of Polyacetal

Polyacetal / Acrylate

In the case of modification of polyacetal with polyacrylate

the advantages are better heat aging and better weathering
 Blends of PPO

Polyphenylene oxide is completely miscible with

polystyrene in all proportions. The glass transition
temperature of these blends change smoothly with
composition. These blends with 25-60% (weight) of PPO,
designed for injection or blow moulding, extrusion
calendering, thermoforming and reinforced with 0-30 weight
percentage glass fiber. They have good processability,
toughness, flame retardance, dimensional stability, resistance
to hot water, economy, HDT (95-150°C), low density and
moisture absorption.
 Blends of PPO

PPO / Nylons

These are blends (compatibilized) with 40-60 weight percentage of

nylon. PPO provide excellent heat resistance, toughness and nylon
(crystalline) resists oils, gasoline and solvent, PPO / Nylons alloys
have a lower density, higher toughness and show less tool/machine
wearcompared to machine filled Nylon. Polyamide grades are used
for automotive body panels which require paint oven temperature
upto 175°C. Large parts can be processed with blow molding
grades or from thermoformed sheets. PPO/Nylon grades are used
in fluid handling applications which require chemical resistance,
dimensional stability and heat resistance