Contents	6
	Contributors	8
	Multicomponent Polymer Material Processing	11
	1 Multi Component Materials	12
	1.1 Introduction and Definition	12
	1.2 Why Multicomponent Materials?	13
	1.3 Recent Technologies	15
	1.3.1 Extrusion	16
	1.3.2 Extrusion Covering	16
	1.3.3 Film Blowing	16
	1.3.4 Calendering	17
	1.3.5 Sheet Thermoforming	17
	1.3.6 Blow Molding	17
	1.3.7 Casting	18
	1.3.8 Compression Molding	18
	1.3.9 Transfer Molding	18
	1.3.10 Injection Molding	19
	1.3.11 Reaction Injection Molding	19
	1.3.12 Coating	20
	1.3.13 Rotational Molding	20
	1.4 Future Trends for Multicomponent Material Fabrication	20
	References	21
	2 Design for Multicomponent Materials	22
	2.1 Introduction	22
	2.1.1 Fundamentals of Materials Processing and Design	23
	2.1.1.1 Influence of Rheology on Design	29
	2.1.1.2 Influence of Shear Rate on Design	32
	2.1.1.3 Flow Performance and Design	33
	2.1.1.4 Elasticity and Design	34
	2.1.1.5 Molecular Weight and Design	35
	2.1.1.6 Chemical Changes and Design	36
	2.1.1.7 Physical State and Design	36
	2.1.1.8 Other Parameters	36
	2.1.2 Material Selection Approaches (Example) [43]	37
	2.1.3 Case Studies	39
	2.2 Summary	43
	References	44
	3 Design of Mold for Multicomponent Material	46
	3.1 Introduction	46
	3.2 Injection Mold for Multi-materials	49
	3.2.1 Classification of Molding Process	49
	3.2.2 Basic Mold Construction of Injection Mold	53
	3.3 Injection Mold Design	55
	3.3.1 Injection Mold	56
	3.3.2 Two-Plate Mold	61
	3.3.3 Mold Materials	65
	3.3.3.1 Selection of the Mold Materials for the Application	66
	3.3.3.2 Various Mold Materials	66
	3.3.4 Other Considerations for Mold Design	72
	3.3.5 Mold Design by Computer-Aided Design	79
	3.3.5.1 Computer Aided Design System for Mold Design	80
	3.3.5.2 Undercut	82
	3.4 Summary	84
	References	84
	4 Injection Molding for Multicomponent Materials	88
	4.1 Introduction	88
	4.1.1 Basics of Injection Molding	88
	4.1.2 Multi-materials Injection Molding	89
	4.1.3 Multi-materials Injection Molding and Quality Control	90
	4.2 Multi-materials Injection Molding	91
	4.2.1 Multi-component Injection Molding	92
	4.2.1.1 Co-injection Molding	92
	4.2.1.2 Bi-Injection Molding	95
	4.2.1.3 Interval Injection Molding	96
	4.2.2 Multi-shot Injection Molding	97
	4.2.2.1 Transfer Multi-shot Molding	98
	4.2.2.2 Core Back Multi-shot Molding	98
	4.2.2.3 Rotary Platen Multi-shot Molding	99
	4.2.3 Over (Insert) Injection Molding	103
	4.2.4 Others	106
	4.3 Prospects on Multi-materials Injection Molding	109
	4.3.1 Micro-powder Injection Molding	109
	4.4 Summary	112
	References	113
	5 Extrusion of Multicomponent Product	117
	Abstract	117
	5.1 Introduction	117
	5.2 Extrusion	117
	5.3 Process and types of extrusion	118
	5.3.1 Hot Extrusion	119
	5.3.2 Cold Extrusion	120
	5.3.3 Warm Extrusion	121
	5.4 Extrusion Defects	121
	5.5 Equipment	121
	5.5.1 Forming Internal Cavities	122
	5.5.2 Direct Extrusion	123
	5.5.3 Indirect Extrusion	124
	5.5.4 Hydrostatic Extrusion	124
	5.5.5 Drives	125
	5.5.6 Die Design	125
	5.5.6.1 Die Forming (Plastics)	126
	5.5.7 Process	126
	5.6 Sheet/Film Extrusion	127
	5.6.1 Blown Film Extrusion	127
	5.7 Over Jacketing	128
	5.8 Fiber Drawing of Polymers	130
	5.8.1 Spinning Stability	131
	5.8.2 Tube Forming	131
	5.8.3 Profile Extrusion	131
	5.9 Coextrusion	132
	5.10 Case Study I	133
	5.10.1 Blown Film Extrusion	133
	5.10.2 Background Theory on Polymers	134
	5.10.3 The Film Blowing Process	134
	5.10.4 Advantages	135
	5.10.5 Disadvantages	135
	5.10.6 Common Problems	135
	5.11 Summary	136
	References	138
	6 Compression for Multiphase Products	140
	6.1 Introduction to Compression Molding	140
	6.2 Design of Compression Molding	141
	6.3 Hydraulic System and Mold	142
	6.4 Types of Mold	145
	6.5 Mold Design	146
	6.6 Control and Operation	148
	6.7 Flow Property of Preform	152
	6.8 Advantages and Disadvantages of Compression Molding	153
	6.9 Transfer Molding	153
	6.10 Types of Transfer Molding	154
	6.10.1 Pot Type Transfer Molding (True Transfer Molding)	154
	6.10.2 Plunger Transfer Molding	155
	6.11 Process Characteristics	156
	6.12 Test Methods Used Before Molding	157
	6.13 Advantages and Disadvantages of Transfer Molding	158
	6.14 Comparison of Transfer and Compression Molding	158
	6.15 Molding Temperatures of Common Thermosetting Polymers	160
	6.16 Molding of Composites	161
	References	161
	7 Paints and Coating of Multicomponent Product	163
	7.1 Introduction	164
	7.1.1 Film Formation	165
	7.1.1.1 Crosslinking Film Formation	166
	7.1.1.2 Evaporation Based Film Formation	167
	7.1.1.3 Coalescence Based Film Formation	167
	7.1.2 Thermoplastic Polymers	168
	7.1.3 Thermoset Polymers	169
	7.1.4 Curing Methods	170
	7.1.4.1 Physical Curing	170
	7.1.4.2 Chemical Curing	170
	7.1.4.3 Curing with Heat Carriers	171
	7.1.4.4 Curing with Radiation	171
	7.1.4.5 Curing by Electrical Methods	172
	7.2 Paint Coating	172
	7.2.1 Composition of Paints and Film Formation	172
	7.2.2 Classification of Paints	173
	7.2.3 Paint Coatings	174
	7.2.3.1 Primers	174
	7.2.3.2 Intermediate Coats	175
	7.2.3.3 Finish Coats	175
	7.2.3.4 Stripe Coats	175
	7.2.3.5 The Paint System	175
	7.2.4 Main Generic Types of Paint and Their Properties	176
	7.2.5 Prefabrication Primers	176
	7.2.5.1 Etch Primers	177
	7.2.5.2 Epoxy Primers	177
	7.2.5.3 Zinc Epoxy Primers	178
	7.2.5.4 Zinc Silicate Primers	178
	7.2.6 Application of Paint Coatings	178
	7.2.6.1 Brushing	178
	7.2.6.2 Roller	178
	7.2.6.3 Air Spray	179
	7.2.6.4 Airless Spray	179
	7.2.7 Conditions of Application	179
	7.2.8 Coating Applicator Training and Certification	180
	7.3 Coating of Fabrics and Textile or Leather	180
	7.4 Spray Coating	183
	7.4.1 Overview	183
	7.4.2 Airless Atomization	185
	7.4.2.1 Advantages	186
	7.4.2.2 Disadvantages	186
	7.4.3 Flame Spray Coating	186
	7.4.4 Spray Transfer Efficiency	187
	7.5 Powder Coating	188
	7.5.1 Powder Production and Part Preparation	189
	7.5.2 Application Techniques	189
	7.5.2.1 Electrostatic Spray	190
	Powder Coating Guns	191
	7.5.2.2 Fluidized Bed	191
	7.5.2.3 Tribocharge Spraying	193
	7.5.3 Powder Coating Equipment	193
	7.5.4 Advantages and Disadvantages	195
	7.5.5 Curing of Powder Coatings	196
	7.5.6 Developments in Powder Coating	196
	7.5.7 Applications	198
	7.6 Electrostatic Coating	199
	7.6.1 Working	200
	7.6.2 Benefits and Applications	200
	7.7 Electrodeposition Coating	201
	7.7.1 Process Parameters	201
	7.7.1.1 Throwing Power	201
	7.7.1.2 Maintaining a Steady State	201
	7.7.1.3 Rupture Voltage	201
	7.7.2 Equipment	202
	7.7.2.1 Conveyors	202
	7.7.2.2 Metal Preparation	202
	7.7.2.3 Tank Enclosures	202
	7.7.2.4 Dip Tanks	202
	7.7.2.5 Rectifiers	203
	7.7.2.6 Counter Electrodes	203
	7.7.2.7 Agitation	203
	7.7.2.8 Temperature Control	203
	7.7.2.9 Ultrafilter	203
	7.7.2.10 Paint Filters	203
	7.7.2.11 Paint Makeup	203
	7.7.2.12 Deionized Water	204
	7.7.2.13 Bake or Cure	204
	7.7.3 Cathodic Electro Deposition	204
	7.7.4 Special Features	205
	7.8 Floc Coating	205
	7.8.1 Carbon Fiber Based Floc Coatings	205
	7.9 Dip Coating	206
	7.9.1 Process	206
	7.9.2 Dip Coating Techniques	208
	7.9.2.1 Self-assembly	208
	7.9.2.2 Sol-Gel Technique	209
	7.9.2.3 Layer-by-Layer Assembly	209
	7.9.3 Advance Developments	210
	7.9.4 Advantages	212
	7.9.5 Disadvantages	213
	7.10 Spin Coating Process	213
	7.10.1 The Key Stages in Spin Coating	213
	7.10.2 Common Defects and Developments	214
	7.10.3 Advantages and Disadvantages	216
	7.11 Pinhole Free Thin Coating	216
	7.12 Coating Based on the Application	217
	7.12.1 Wire and Cable Coating	217
	7.12.2 Planar Coating	218
	7.12.3 Contour Coating	218
	7.12.4 Roll Coating	219
	7.13 Conclusion	219
	References	219
	Applications of Multicomponent Product	233
	8 Multilayer Polymer Films	234
	8.1 The Significance of Multilayer Polymer Films	234
	8.2 Methods of Preparation	235
	8.2.1 Layer-by-Layer Assembly	235
	8.2.2 Extrusion	236
	8.2.3 Co-extrusion [5]	237
	8.2.4 Co-injection Stretch Blow Moulding [6]	237
	8.2.5 Lamination	238
	8.2.5.1 Extrusion Lamination	238
	8.2.5.2 Adhesive Lamination [6]	238
	8.2.5.3 Heat-Welded Lamination	239
	8.2.6 Coating	239
	8.2.7 Metallization	240
	8.2.8 Thermal Spray Processing of Polymers (“Gun”)	240
	8.2.9 Spin Coating	240
	8.2.10 Solvent Casting, Painting	241
	8.3 Characterization	241
	8.3.1 Barrier Properties	241
	8.3.1.1 Oxygen Transmission Rate (OTR)	242
	8.3.1.2 Water Vapour Permeability	245
	8.3.2 Morphological Characterization	246
	8.3.3 Mechanical Study	250
	8.3.4 X-Ray Diffraction	251
	8.3.5 Fourier Transform Infrared Spectrometer	253
	8.3.6 Thermal Analysis	254
	8.4 Application	256
	8.4.1 Food Packaging	256
	8.4.2 Agricultural Application	258
	8.4.2.1 Mulching	259
	8.4.2.2 Multilayer Films for Green Houses	260
	8.4.2.3 Controlled Release of Agricultural Chemicals	261
	8.4.2.4 Polymeric Windbreaks and Protective Nets	261
	8.4.3 Medical Application	261
	8.4.4 Optical Devices	261
	8.5 Conclusion	262
	References	262
	9 Hybrid Systems for Multi-layer Fuel and Air Hoses in Automobiles	264
	Abstract	264
	9.1 Introduction	264
	9.2 Multilayer Hybrid Hoses Made Using Rubber	267
	9.3 Fluoropolymer Based Hoses	269
	9.4 Polyamide Based Multilayer Hybrid Hoses	272
	9.5 Fuel Hose for Hydrogen Transport	276
	9.6 Hoses Made from Hybrid Yarns	277
	9.7 Air Hoses	279
	9.8 Standards for Evaluating Multilayer Hoses	281
	9.9 Conclusions	281
	Acknowledgments	281
	References	282
	10 Multi Layer Pipes	283
	10.1 Introduction	283
	10.2 Materials of Multi-layer Pipes	284
	10.3 Production of Multi-layer Pipes	285
	10.4 Silane Crosslinking Technology	285
	10.5 Failure Analysis of Multi-layer Pipes	286
	10.6 Lifetime Estimation	288
	10.7 Fittings for MLP	289
	10.8 Environmental Impact of Multi-layer Pipes	289
	10.9 Application of Multi-layer Pipes	291
	10.10 Coating for Corrosion Resistance	291
	10.10.1 Corrosion Control Methods	294
	10.10.2 Erosion Resistance of Fusion Bonded Epoxy Coating	295
	10.11 Analysis of Failure of Fusion Bonded Powder Epoxy Internal Coating	300
	10.11.1 Differential Scanning Calorimetry (DSC) Analyses	301
	10.12 Summary	302
	References	302
	11 Multilayer (Fuel) Storage Tank	304
	11.1 Introduction	304
	11.1.1 Need for Multilayer Storage Tanks	305
	11.1.2 Overview of Multilayer Assembly	305
	11.2 Techniques Involved in Multilayer Coating	306
	11.2.1 Spin Coating	307
	11.2.2 Dip Coating	308
	11.2.3 Spray Coating	309
	11.2.4 Vapour Deposition Process	309
	11.2.4.1 Physical Vapor Deposition (PVD)	310
	11.2.4.2 Chemical Vapor Deposition (CVD)	310
	11.2.5 Plasma Spray Coating	311
	11.3 Materials and Particles Used for the Construction of LBL Assembled Storage Tanks	311
	11.4 Development of Multilayered Films for Fuel Storage Applications	312
	11.4.1 Multilayer Assembly for Transport Applications	312
	11.4.2 Multilayer Assembly for Hydrogen Barrier Applications	313
	11.4.3 Multilayer Assembly for Oxygen Barrier Applications	316
	11.4.4 Multilayer Assembly for Hydrogen and Helium Barrier Applications	319
	11.4.5 Multilayer Assembly for Methanol Barrier Applications	320
	11.4.6 Multilayer Assembly for Gas Turbine Applications	323
	11.5 Summary	324
	References	325
	12 Multilayer Bottles	328
	12.1 Why Do We Need Multilayer Polymer Films?	328
	12.1.1 Materials Used for Multilayer Bottles	331
	12.1.2 Processing of Multilayer Bottles	332
	12.1.2.1 Extrusion Multilayer	334
	12.1.2.2 Injection Multilayer	336
	12.1.2.3 Stretch Blow Molding	337
	12.1.2.4 Preform or Bottle Coating	337
	12.1.2.5 Bottle Treatment	338
	12.1.3 Properties of Multilayered Bottles	339
	12.1.3.1 Impact Strength	340
	12.1.3.2 Chemical Resistance	340
	12.1.3.3 Barrier Properties	340
	12.1.3.4 Physical Properties	341
	12.1.4 Tests on Multi Layer Plastic Bottles	343
	12.1.5 Applications of Multilayered Bottles	349
	12.1.6 Conclusion	350
	References	350
	13 Multiphase Materials for Tire Applications	352
	13.1 Introduction	352
	13.1.1 Multiphase Materials	352
	13.1.2 Need for a Multiphase Material	353
	13.2 Fillers Used for the Preparation of Rubber Compounds for Tyre Application	354
	13.2.1 Styrene Butadiene Rubber (SBR)	354
	13.2.2 Natural Rubber (NR)	354
	13.2.3 Carbon Nanomaterials Based Elastomers	355
	13.2.3.1 Carbon Black	355
	13.2.3.2 Carbon Nanotubes	356
	13.2.3.3 Graphite Nanosheets, Graphene and GnO to GnPs	356
	13.3 Researches Towards Rubber and Filler Based Composites	357
	13.3.1 Silica Based Natural Rubber Composites	357
	13.3.1.1 NBR/EPDM Silica Reinforced Composites	358
	13.3.2 Clay/NR Rubber Composites	358
	13.3.2.1 Clay/EPDM Rubber Nanocomposites	359
	13.3.2.2 Clay/NBR Nanocomposites	360
	13.3.3 Carbon Nanotubes/Natural Rubber/Carbon Black Composites	361
	13.3.4 Polymer/Carbon Black Composites	362
	13.3.5 Graphene/Natural Rubber Composites	363
	13.3.6 Polypropylene Blended with Scrap Rubber Tyres (SRT) and EPDM	364
	13.3.7 Effect of Water Absorption on Mechanical Properties of Multiphase Material Rubber Blend	365
	13.3.8 Compatibilization of Rubber Based Blends by Filler Modification	365
	13.3.9 Fly Ash Filler with Elastomers	366
	13.3.10 Calcium Carbonate/Rubber Composites	367
	13.4 Rubbers in Tire Applications	368
	13.5 Challenges and Further Research	368
	References	369
	14 Interfacial Compatibilization of Multilayered Products	371
	14.1 Introduction	371
	14.2 Thermodynamics of Multilayered Products	372
	14.2.1 Prediction of Stability in Multilayers	373
	14.3 Compatibilization	373
	14.3.1 Interfacial Compatibilization	374
	14.3.1.1 Inter Diffusion	375
	14.3.1.2 Interfacial Slip	375
	14.3.1.3 Interfacial Reaction	376
	14.3.2 Method of Compatibilization	376
	14.4 Compatibilizers	376
	14.5 Morphology—Interfacial Adhesion of Multilayered Polymer Products	377
	14.6 Conclusion	382
	References	382
	15 Multilayer Nanowires and Miscellaneous Multilayer Products	384
	15.1 Significance of Polymer Multilayer Products	384
	15.2 Polymers as Multilayer Nanowires	385
	15.2.1 General Preparation Methods	385
	15.2.1.1 Electrospinning	386
	15.2.1.2 Stamping or Microtip Writing	386
	15.2.1.3 Electrodeposition	387
	15.2.1.4 Nanoskiving	387
	15.2.1.5 Micromolding	387
	15.2.2 Alignment of Nanowires	389
	15.2.3 Characterization	389
	15.2.3.1 Morphological Characterization	390
	15.2.4 Applications	392
	15.3 Multilayer Films for Pharmaceutical Applications	394
	15.4 Multilayer Polymer Films for Medical Applications	397
	15.5 Multilayer Polymer Films for Sensor Applications	400
	15.6 Multilayer Polymer Films in Agricultural Field	404
	15.7 Multilayer Polymer Films for Miscellanious Applications	405
	15.8 Conclusion	409
	References	409