Demand for plastic products is continuously growing with population increase and higher living standards. Imparting colours to plastics is a combination of art and science and plays a key role in production of attractive products for a...
moreDemand for plastic products is continuously growing with population increase and higher living standards. Imparting colours to plastics is a combination of art and science and plays a key role in production of attractive products for a variety of consumer demands. It requires a good understanding of the processing parameters and formulation of compositions including colour pigments and their dispersion. This thesis presents experimental observations and statistical analysis to investigate scientific reasons for colour mismatches in compounded plastics. Material processing issues were investigated. Six methods were used to study and improve the understanding of colour matching, colour stability, and consistency of compounded plastic materials in order to minimize wastage. The first was Data Mining, in which historical data was analyzed to select formulations, particularly for pigments and polycarbonate blends of compounded plastics that were known to suffer from colour mismatch. The second method involved the use of historical data and an artificial neural network (ANN) to predict the resultants colours based upon pigment formulations. In the third method, a parametric study was utilized to investigate issues in the dispersion of pigments due to the effects of processing conditions. Temperature and feed rate were found to have major effects on colour deviations. The fourth method involved studying the compounding process for blends of two polycarbonate resins (PC) of different melt flow index (MFI). It was also found that the PC composition of 30-70 wt.% was superior in terms of colour matching. The fifth method studied effects of rheology. The viscosity data collected allows predictions of viscosity changes with varying temperatures, which had a direct impact on polymer colour changes during processing of blends. The sixth method looked at the effects of processing parameters on dispersion, pigment size distribution (PSD), and the morphology of pigments in polycarbonate compounds. In general, the total colour difference decreased when processing parameters were increased. De-agglomeration occurred in zones of high shear and was found to significantly increase the number of particles and lower colour differences. I would like to dedicate this work for my parents, who passed away during my study. My parents were the most beautiful things I ever had. I attribute my success in life to the moral, intellectual, and physical education I received from them. I would also like to show gratitude to my family for their support and encouragement throughout my research and higher education. This support has been vital, and I shall never forget it. Much love and thanks are extended to my friends and others who have lent their support and encouragement through this endeavour. I would like to express my thanks to my supervisor Professor Ghaus Rizvi for his patient guidance, encouragement and useful critiques of this research work. I also want to extend my deepest appreciation to him for giving me every opportunity to enhance my graduate experience from introducing me to an industrial organization facility, to allowing me to attend conferences, seminars and workshops across North America and North Africa to present my work. I am thankful to my supervisory committee members Dr. Hossam Kishawy and Dr. Yuping He for their guidance and advice. I am particularly grateful for the assistance given, not only for their technical knowledge, but also for showing me how to differentiate the important things and keep the most basic questions in mind. I would also like to express great appreciation to the people who helped and supported me during the preparation of this thesis. I also acknowledge the support and guidance by Professor Amir Hossein Behravesh. I would also like to take the time in expressing great thanks to my colleagues in our Mechanical Engineering Lab, Dr. Usman Saeed and PhD students Shahid and Rasel for their kind collaboration and efforts. Major funding for this research was graciously by SABIC IP and Natural Sciences and Engineering Research Council (NSERC) of Canada .I would like to extend my gratitude for support provided by the staff at SABIC IP Cobourg, Canada for their assistance in the experiments, lab tests: Daniel Ross. Joseph Wembley, James Price, and Richard Clarke. This journey iv would not have been possible without their help and support. The material samples used throughout the experimental process were generously provided SABIC IP.