Osswald, Menges
`Material Science of Polymers for Engineers
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 1
`
`

`

`Yita v. MacNeil IP, IPR2020-01139, Page 2
`
`MacNeil Exhibit 2178
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 2
`
`

`

`Tim A. Osswald
`Georg Menges
`
`Material Science
`of Polymers
`for Engineers
`
`3rd Edition
`
`Hanser Publishers, Munich
`
`
`
`
`
`
`
`
`
`
`
`
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`
` Hanser Publications, Cincinnati
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 3
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`

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`!e Author:
`Prof. Dr. Tim A. Osswald,
`University of Wisconsin-Madison, Polymer Processing Research Group,
`Department of Mechanical Engineering, 1513 University Avenue, Madison, USA
`
`Prof. Dr.-Ing. Georg Menges,
`Am Beulardstein 19, Aachen, Germany
`
`Distributed in North and South America by:
`Hanser Publications
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`Distributed in all other countries by
`Carl Hanser Verlag
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`especially identi"ed, is not to be taken as a sign that such names, as understood by the Trade Marks and
`Merchandise Marks Act, may accordingly be used freely by anyone.
`While the advice and information in this book are believed to be true and accurate at the date of going to
`press, neither the authors nor the editors nor the publisher can accept any legal responsibility for any errors
`or omissions that may be made. !e publisher makes no warranty, express or implied, with respect to the
`material contained herein.
`
`Library of Congress Cataloging-in-Publication Data
`
`to follow
`
`Bibliogra"sche Information Der Deutschen Bibliothek
`Die Deutsche Bibliothek verzeichnet diese Publikation in der Deutschen Nationalbibliogra"e;
`detaillierte bibliogra"sche Daten sind im Internet über <http://dnb.d-nb.de> abru#ar.
`
`ISBN 978-1-56990-514-2
`E-Book-ISBN 9781569905241
`
`All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means,
`electronic or mechanical, including photocopying or by any information storage and retrieval system,
`without permission in writing from the publisher.
`
`© Carl Hanser Verlag, Munich 2010
`Production Management: Ste$en Jörg
`Coverconcept: Marc Müller-Bremer, www.rebranding.de, München
`Coverdesign: Stephan Rönigk
`Typeset, printed and bound by Kösel, Krugzell
`Printed in Germany
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 4
`
`

`

`Preface to the
`First Edition
`
`This book is designed to provide a polymer materials science background to engi-
`neering students and practicing engineers. It is written on an intermediate level
`for students, and as an introduction to polymer materials science for engineers.
`The book presents enough information that, in conjunction with a good design
`background, it will enable the engineer to design polymer components.
`Materials Science of Polymers for Engineers is based on the German textbook, Werk-
`stoffkunde Kunststoffe (G. Menges, Hanser Publishers, 1989), and on lecture notes
`from polymer materials science courses taught at the Technical University of
`Aachen, Germany, and at the University of Wisconsin-Madison.
`The chapters on thermal and electrical properties are loose translations from Werk-
`stoffkunde Kunststoffe, and many figures throughout the manuscript were taken
`from this book. We have chosen a unified approach and have divided the book into
`three major sections: Basic Principles, Influence of Processing on Properties, and
`Engineering Design Properties. This approach is o!en referred to as the four P’s:
`polymer, processing, product and performance. The first section covers general
` topics such as historical background, basic material properties, molecular structure
`of polymers and thermal properties of polymers. The second section ties processing
`and design by discussing the effects of processing on properties of the final polymer
`component. Here, we introduce the reader to the rheology of polymer melts, mixing
`of polymer blends, development of anisotropy during processing and solidification
`processes. In essence, in this section we go from the melt (rheology) to the finished
`product (solidification). The third section covers the different properties that need to
`be considered when designing a polymer component, and analyzing its performance.
`These properties include mechanical properties, failure of polymers, electrical prop-
`erties, optical properties, acoustic properties, and permeability of polymers. The
`authors cannot acknowledge everyone who helped in one way or another in the prep-
`aration of this manuscript. We would like to thank the students of our polymer mate-
`rials science courses who in the past few years endured our experimenting and
`trying out of new ideas. The authors are grateful to the staff and faculty of the
`Mechanical Engineering Department at the University of Wisconsin-Madison, and
`the Institut für Kunststoffverarbeitung (IKV) at the Technical University of Aachen
`for their support while developing the courses which gave the base for this book. We
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 5
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`

`

`VI
`
`Preface to the First Edition
`
`are grateful to Richard Theriault for proofreading the entire manuscript. We also
`thank the following people who helped proofread or gave suggestions during the
`preparation of the book: Susanne Belovari, Bruce A. Davis, Jeffrey Giacomin, Paul J.
`Gramann, Matthew Kaegebein, Gwan-Wan Lai, Maria del Pilar Noriega E., Antoine C.
`Rios B., Linards U. Stradins and Ester M. Sun, Susanne Belovari and Andrea Jung-
`Mack are acknowledged for translating portions of Werkstoffkunde Kunststoffe from
`German to English. We also thank Tara Ruggiero for preparing the camera-ready
`manuscript. Many of the figures were taken from class notes of the mechanical engi-
`neering senior elective course Engineering Design with Polymers. Special thanks
`are offered to Lynda Litzkow, Philipp Ehrenstein and Bryan Hutchinson for the
`superb job of drawing those figures. Matthias Mahlke of Bayer AG in Leverkusen,
`Germany, Laura Dietsche, Joseph Dooley and Kevin Hughes of Dow Chemical in Mid-
`land, Michigan, and Mauricio DeGreif and Juan Diego Sierra of the ICIPC in Medellín,
`Colombia, are acknowledged for some of the figures. Thanks are due to Marcia
` San ders for copy editing the final manuscript. We are grateful to Wolfgang Glenz,
`Martha Kürzl, Ed Immergut and Carol Radtke of Hanser Publishers for their support
`throughout the development of this book. Above all, the authors thank their wives
`for their patience.
`Summer 1995
`Tim A. Osswald
`Madison, Wisconsin, USA
`
`Georg Menges
`Aachen, Germany
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`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 6
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`

`

`Preface to the
`Third Edition
`
`3 Zeilen Übersatz
`
`The first edition of this book was adopted by several universities in North and
`South America, Europe, and Asia as a textbook to introduce engineering students
`to the materials science of polymers. The book was also translated into Japanese in
`1998, Korean in 1999, and Spanish in 2008. The professors who taught with the
`first and second editions as well as their students liked the unified approach we
`took. The changes and additions that were introduced in this edition are based on
`suggestions from these professors and their students, as well as from our own
`experience using it as a class textbook.
`A!er two revisions and two decades of teaching it has become clear that sustaina-
`bility and profits are important when dealing with polymeric materials. Therefore
`the 4P’s of the first edition have expanded to the 6P’s in the third edition: polymer,
`processing, product, performace, post-consumer life, and profit. In the last 18
`years, this book has become a reference for many practicing engineers, most of
`whom were introduced to the book as students. The first and second editions were
`praised because of the vast number of graphs and data that can be used as refer-
`ences. We have further strengthened this attribute by expanding a comprehensive
`table in the appendix that contains material property graphs for several polymers.
`Furthermore, in this edition we added color to the figures and graphs, making the
`book more appealing to the reader.
`With this edition we owe our gratitude to Dr. Christine Strohm for editing the book
`and catching those small typos and inconsistencies in the text and equations. We
`thank Dr. Nadine Warkotsch and Steffen Joerg of Hanser Publishers for their coop-
`eration during the production of this book. We are grateful to Luz Mayed D.
`Nouguez and Tobias Mattner for the superb job drawing the figures, and to Tobias
`Mattner for his suggestions on how to make many of the figures more understand-
`able. A special thanks to Katerina Sánchez for the graphs related to recycling of
`plastics in Chapter 1 and to Nora Catalina Restrepo for generating the polymer
`statistic graphs in Chapter 2. My graduate students Roberto Monroy, Luisa López,
`Tom Mulholland, Jakob Onken, Camilo Pérez, Daniel Ramírez, Jochen Wellekoetter
`and Yuxiao Zhang, organized by William Aquite, supplied extra problems and solu-
`tions for the third edition; thank you. Special thanks to Diane for – as always –
`serving as a sounding board and advisor during this project.
`Spring 2012
`Tim A. Osswald
`Madison, Wisconsin, USA
`
`Georg Menges
`Aachen, Germany
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 7
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`

`

`Yita v. MacNeil IP, IPR2020-01139, Page 8
`
`MacNeil Exhibit 2178
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 8
`
`

`

`Contents
`
`Preface to the First Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`
`V
`
`Preface to the Third Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
`
`Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`!
`$.$ The % P’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`$.& General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`$.# Identification of Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`$.’ Sustainability – The %th P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`
`" Historical Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&.$ From Natural to Synthetic Rubber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&.& Cellulose and the $$),))) Idea . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&.# Galalith – The Milk Stone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&.’ Leo Baekeland and the Plastics Industry . . . . . . . . . . . . . . . . . . . . . . . . . .
`&.( Herman Mark and the American Polymer Education . . . . . . . . . . . . . . . .
`&.% Wallace Hume Carothers and Synthetic Polymers . . . . . . . . . . . . . . . . . . .
`&.*
` Polyethylene – A Product of Brain and Brawn . . . . . . . . . . . . . . . . . . . . . .
`&., The Super Fiber and the Woman Who Invented It . . . . . . . . . . . . . . . . . . .
`&.+ One Last Word – Plastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`
`# Structure of Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.$ Macromolecular Structure of Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.& Molecular Bonds and Inter-Molecular Attraction . . . . . . . . . . . . . . . . . . . .
`#.# Molecular Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`
`#
`#
`%
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`
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`($
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 9
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`

`

`X
`
`Contents
`
`#.’ Conformation and Configuration of Polymer Molecules . . . . . . . . . . . . . .
`#.( Arrangement of Polymer Molecules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.(.$ Thermoplastic Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.(.& Amorphous Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.(.# Semi-Crystalline Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.(.’ Thermosets and Cross-Linked Elastomers . . . . . . . . . . . . . . . . . . . .
`#.% Copolymers and Polymer Blends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.* Polymer Additives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.*.$ Flame Retardants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.*.& Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.*.# Antistatic Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.*.’ Fillers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`#.*.( Blowing Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`
`$ Thermal Properties of Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.$ Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.$.$ Thermal Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.$.& Specific Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.$.# Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.$.’ Thermal Diffusivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.$.( Linear Coefficient of Thermal Expansion . . . . . . . . . . . . . . . . . . . .
`’.$.% Thermal Penetration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.$.* Glass Transition Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.$., Melting Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.& Measuring Thermal Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.&.$ Differential Thermal Analysis (DTA) . . . . . . . . . . . . . . . . . . . . . . . .
`’.&.& Differential Scanning Calorimeter (DSC) . . . . . . . . . . . . . . . . . . . . .
`’.&.# Thermomechanical Analysis (TMA) . . . . . . . . . . . . . . . . . . . . . . . . .
`’.&.’ Thermogravimetry (TGA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`’.&.( Density Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`
`% Rheology of Polymer Melts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.$ Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.$.$ Continuum Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.$.& The Generalized Newtonian Fluid . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.$.# Normal Stresses in Shear Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.$.’ Deborah Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`
`(%
`(+
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`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 10
`
`

`

`
`
`Contents
`
`XI
`
`(.& Viscous Flow Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.&.$ The Power Law Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.&.& The Bird-Carreau-Yasuda Model . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.&.# The Bingham Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.&.’ Elongational Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.&.( Rheology of Curing Thermosets . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.&.% Suspension Rheology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.# Simplified Flow Models Common in Polymer Processing . . . . . . . . . . . . .
`(.#.$ Simple Shear Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.#.& Pressure Flow Through a Slit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.#.# Pressure Flow through a Tube – Hagen-Poiseuille Flow . . . . . . . .
`(.#.’ Couette Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.’ Viscoelastic Flow Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.’.$ Differential Viscoelastic Models . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.’.& Integral Viscoelastic Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.( Rheometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.(.$ The Melt Flow Indexer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.(.& The Capillary Viscometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.(.# Computing Viscosity Using the Bagley and
`Weissenberg-Rabinowitsch Equations . . . . . . . . . . . . . . . . . . . . . . .
`(.(.’ Viscosity Approximation Using the Representative
`Viscosity Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.(.( The Cone-Plate Rheometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.(.% The Couette Rheometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.(.* Extensional Rheometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`(.% Surface Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`
`Introduction to Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&
`%.$ Extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.$.$ The Plasticating Extruder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.$.$.$ The Solids Conveying Zone . . . . . . . . . . . . . . . . . . . . . . . . .
`%.$.$.& The Melting Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.$.$.# The Metering Zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.$.& Extrusion Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.$.&.$ Sheeting Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.$.&.& Tubular Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.& Mixing Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.&.$ Distributive Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.&.$.$ Effect of Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`
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`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 11
`
`

`

`XII
`
`Contents
`
`$,’
`%.&.& Dispersive Mixing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`$,’
`%.&.&.$ Break-Up of Particulate Agglomerates . . . . . . . . . . . . . . . .
`$,%
`%.&.&.& Break-Up of Fluid Droplets . . . . . . . . . . . . . . . . . . . . . . . . . .
`$,+
`%.&.# Mixing Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`$+)
`%.&.#.$ Static Mixers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`$+)
`%.&.#.& Banbury Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`$+&
`%.&.#.# Mixing in Single Screw Extruders . . . . . . . . . . . . . . . . . . .
`$+’
`%.&.#.’ Co-Kneader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`$+(
`%.&.#.( Twin Screw Extruders . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`$+,
`%.&.’ Energy Consumption During Mixing . . . . . . . . . . . . . . . . . . . . . . . .
`$++
`%.&.( Mixing Quality and Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`%.&.% Plasticization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &)$
`%.# Injection Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &)%
`%.#.$ The Injection Molding Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &)*
`%.#.& The Injection Molding Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . &$)
`%.#.&.$ The Plasticating and Injection Unit . . . . . . . . . . . . . . . . . . &$)
`%.#.&.& The Clamping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&$$
`%.#.&.# The Mold Cavity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&$#
`%.’ Special Injection Molding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &$%
`%.’.$ Multi-Component Injection Molding . . . . . . . . . . . . . . . . . . . . . . . . &$%
`%.’.& Co-Injection Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&$,
`%.’.# Gas-Assisted Injection Molding (GAIM) . . . . . . . . . . . . . . . . . . . . . .
`&$+
`%.’.’ Injection-Compression Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&&$
`%.’.( Reaction Injection Molding (RIM) . . . . . . . . . . . . . . . . . . . . . . . . . . &&&
`%.’.% Liquid Silicone Rubber Injection Molding . . . . . . . . . . . . . . . . . . . . &&(
`%.( Secondary Shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &&%
`%.(.$ Fiber Spinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &&%
`%.(.& Film Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &&*
`%.(.&.$ Cast Film Extrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &&*
`%.(.&.& Film Blowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &&,
`%.(.# Blow Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &#)
`%.(.#.$ Extrusion Blow Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . &#)
`%.(.#.& Injection Blow Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . &#&
`%.(.#.# Thermoforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &##
`%.% Calendering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &#(
`%.* Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &#,
`%., Compression Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &’)
`%.+ Foaming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &’&
`%.$) Rotational Molding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &’’
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 12
`
`

`

`
`
`Contents
`
`XIII
`
`%.$$ Computer Simulation in Polymer Processing . . . . . . . . . . . . . . . . . . . . . . . &’(
`%.$$.$ Mold Filling Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &’%
`%.$$.& Orientation Predictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &’,
`%.$$.# Shrinkage and Warpage Predictions . . . . . . . . . . . . . . . . . . . . . . . . &’+
`References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &%)
`
`’ Anisotropy Development During Processing . . . . . . . . . . . . . . . . . &%#
`*.$ Orientation in the Final Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &%#
`*.$.$ Processing Thermoplastic Polymers . . . . . . . . . . . . . . . . . . . . . . . . &%#
`*.$.& Processing Thermoset Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . .
`&*$
`*.& Predicting Orientation in the Final Part . . . . . . . . . . . . . . . . . . . . . . . . . . . &*(
`*.&.$ Planar Orientation Distribution Function . . . . . . . . . . . . . . . . . . . . &*%
`*.&.& Single Particle Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &*,
`*.&.#
`Jeffery’s Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &*+
`*.&.’ Folgar-Tucker Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &,)
`*.&.( Tensor Representation of Fiber Orientation . . . . . . . . . . . . . . . . . .
`&,$
`*.&.(.$ Predicting Orientation in Complex Parts Using
`Computer Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &,&
`*.# Fiber Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &,*
`References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &+#
`
`( Solidification of Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &+(
`,.$ Solidification of Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &+(
`,.$.$ Thermodynamics During Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . &+(
`,.$.& Morphological Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &++
`,.$.# Crystallization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #))
`,.$.’ Heat Transfer During Solidification . . . . . . . . . . . . . . . . . . . . . . . . . #)#
`,.& Solidification of Thermosets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #)*
`,.&.$ Curing Reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #),
`,.&.& Cure Kinetics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #)+
`,.&.# Heat Transfer During Cure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #$’
`,.# Residual Stresses and Warpage of Polymeric Parts . . . . . . . . . . . . . . . . . . #$%
`,.#.$ Residual Stress Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #$+
`,.#.$.$ Residual Stress Model Without Phase Change Effects . . . #&$
`,.#.$.& Model to Predict Residual Stresses with
`Phase Change Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #&&
`,.#.& Other Simple Models to Predict Residual Stresses and Warpage . #&’
`,.#.&.$ Uneven Mold Temperature . . . . . . . . . . . . . . . . . . . . . . . . . #&%
`,.#.&.& Residual Stress in a Thin Thermoset Part . . . . . . . . . . . . . #&*
`,.#.&.# Anisotropy Induced Curvature Change . . . . . . . . . . . . . . . #&,
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 13
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`

`

`XIV
`
`Contents
`
`,.#.# Predicting Warpage in Actual Parts . . . . . . . . . . . . . . . . . . . . . . . . . #&+
`References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ##%
`
`) Mechanical Behavior of Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . #’$
`+.$ Basic Concepts of Stress and Strain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #’$
`+.$.$ Plane Stress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #’&
`+.$.& Plane Strain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #’#
`+.& Viscoelastic Behavior of Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #’#
`+.&.$ Stress Relaxation Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #’’
`+.&.& Time-Temperature Superposition (WLF-Equation) . . . . . . . . . . . . . #’%
`+.&.# The Boltzmann Superposition Principle . . . . . . . . . . . . . . . . . . . . . #’*
`+.# Applying Linear Viscoelasticity to Describe the Behavior of Polymers . . #’,
`+.#.$ The Maxwell Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #’+
`+.#.& Kelvin Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #()
`+.#.# Jeffrey Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #(&
`+.#.’ Standard Linear Solid Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #(’
`+.#.( The Generalized Maxwell Model . . . . . . . . . . . . . . . . . . . . . . . . . . . #(%
`+.’ The Short-Term Tensile Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #%$
`+.’.$ Rubber Elasticity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #%&
`+.’.& The Tensile Test and Thermoplastic Polymers . . . . . . . . . . . . . . . . #%*
`+.( Creep Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #*’
`+.(.$
`Isochronous and Isometric Creep Plots . . . . . . . . . . . . . . . . . . . . . . #*,
`+.% Dynamic Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #*+
`+.%.$ Torsion Pendulum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #*+
`+.%.& Sinusoidal Oscillatory Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #,#
` Effects of Structure and Composition on Mechanical Properties . . . . . . . #,(
`+.*.$ Amorphous Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #,(
`+.*.& Semi-Crystalline Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . . #,,
`+.*.# Oriented Thermoplastics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #+)
`+.*.’ Crosslinked Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . #+(
`+., Mechanical Behavior of Filled and Reinforced Polymers . . . . . . . . . . . . . #+*
`+.,.$ Anisotropic Strain-Stress Relation . . . . . . . . . . . . . . . . . . . . . . . . . . #++
`+.,.& Aligned Fiber Reinforced Composite Laminates . . . . . . . . . . . . . . . ’))
`+.,.# Transformation of Fiber Reinforced Composite Laminate
`Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ’)&
`+.,.’ Reinforced Composite Laminates with a Fiber Orientation
`Distribution Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ’)’
`+.+ Strength Stability Under Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ’)(
`References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ’&$
`
`+.*
`
`MacNeil Exhibit 2178
`Yita v. MacNeil IP, IPR2020-01139, Page 14
`
`

`

`
`
`Contents
`
`XV
`
`!* Failure and Damage of Polymers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ’&#
`$).$ Fracture Mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ’&#
`$).$.$ Fracture Predictions Based on the Stress Intensity Factor . . . . . . ’&’
`$).$.& Fracture Predictions Based on an Energy Balance . . . . . . . . . . . . . ’&%
`$).$.# Linear Viscoelastic Fracture Predictions Based on J-Integrals . . . ’&,
`$).& Short-Term Tensile Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ’#)
`$).&.$ Brittle Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ’#)
`$).&.& Ductile Failure . . . . . . . . . . .