Film Processing

Contents

1 Film Processing: Overview and Introductory Rheology

1.1 Introduction

1.2 Cast Film

1.3 Blown Film

1.4 Tentering

1.5 Double Bubble Process

1.6 Volume Contents

1.7 Rheological Considerations

1.7.1 Shear Rheology

1.7.2 Elongational Rheology

1.7.3 Literature Review

2.1 Flat Die Analysis

2.1.1 Introduction

2.1.2 Simple Die Flow

2.1.3 Theoretical One-Dimensional Analysis of the Flat Die

2.1.4 Two-Dimensional Numerical Analysis of the Flat Die

2.1.5 The Multilayer Flat Die

2.2 Spiral Die Analysis

2.2.1 Introduction

2.2.2 Annular Flow Geometry

2.2.3 Basic Design Considerations

2.2.4 Mathematical Modeling

2.3 Die Control System of Film Thickness Distribution

2.3.1 Introduction

2.3.2 Cast Film.

2.3.3 Blown Film

2.3.4 Outlook

3.1 Dynamics, Heat Transfer, and StructureDevelopment in Tubular Film Extrusion of Polymer Melt

3.1.1 Introduction

3.1.2 Rheological Measurement

3.1.3 Local Kinematics

3.1.4 Temperature Profiles

3.1.5 Heat Transfer

3.1.6 Crystallization Rate

3.1.7 Theoretical Analysis

3.1.8 Dimensionless Analysis

3.1.9 Predictions of the Model

3.1.10 Physical Properties of High Molecular Weight HDPE Tubular Film

3.1.11 Scaleup of High Molecular Weight HDPE

3.1.12 Processability

3.2 Kinematics, Dynamics, and Physical Properties of Blown Film

3.2.1 Introduction

3.2.2 Single-Phase Model Dynamics

3.2.3 Fluid-Solid Models

3.2.4 Property Development in Blown Film

3.2.5 Summary

3.4 Optical Properties and Structural

3.4.1

Introduction

3.4.2 Background

3.4.2.1 Structural Characteristics

3.4.2.2 Electromagnetic Theory and Optical Characteristics

3.4.2.4 Orientation

3.4.2.5 Interaction of Electromagnetic Waves with Surfaces

3.4.3 Measurement Methods

3.4.3.2 Measurement of Orientation in Films

4.1.1

Introduction

4.1.2 Analysis of Film Deformation under Steady State

4.1.4 Analysis of Neck-In and Edge Bead Phenomena

Relevance of the Problem in the Film Industry

Draw Resonance in Newtonian Fluids

4.2.4.2 Viscoelastic Fluids

4.2.6 Conclusion

5.4 Coextrusion of Cast Film/Sheet

5.5 Coextrusion Feedblock and Multimanifold Dies

5.7 Coextrusion of Blown Film

5.8 Coextrusion Equipment Considerations and Auxiliaries

3.3 Bubble Instability: ExperimentalEvaluation

3.3.1 Introduction

3.3.2 Theory

3.3.3 Qualitative Experimental Analysis

3.3.4 Quantitative Stability Analysis

3.3.5 Summary

3.4 Optical Properties and Structural Characteristics of Tubular Film

3.4.1 Introduction

3.4.2 Background

3.4.3 Measurement Methods.

3.4.4 Orientation Development in Vitrifying Tubular Film

3.4.5 Structure Development in Crystalline Tubular Film

3.4.6 Mechanism of Haze

4.1 Theoretical Analysis of Film Deformation Behavior in Casting

4.1.1 Introduction

4.1.2 Analysis of Film Deformation under Steady State

4.1.3 Analysis of Film Temperature

4.1.4 Analysis of Neck-In and Edge Bead Phenomena

4.1.5 Influence of Processing Factors on Film Properties

4.1.6 Concluding Remarks

4.2 Analysis of Draw Resonance Instabilityin the Film Casting Process

4.2.1 Introducation

4.2.2 Relevance of the Problem in the Film Industry

4.2.3 Draw Resonance in Newtonian Fluids

4.2.4 Draw Resonance in Non-Newtonian Fluids

4.2.5 Mechanism of Draw Resonance

4.2.6 Conclusion

5 Multilayer Films

5.1 Introduction

5.2 Monolayer Cast Film Extrusion

5.3 Monolayer Blown Film Extrusion

5.4 Coextrusion of Cast Film/Sheet

5.5 Coextrusion Feedblock and Multimanifold Dies

5.6 Coextrusion of Flexible Cast Film

5.7 Coextrusion of Blown Film

5.8 Coextrusion Equipment Considerations and Auxiliaries

5.8.1 Extruder Screws for Coextrusion

5.8.2 Mixers for Coextrusion

5.8.3 Gear Pumps for Coextrusion

5.8.4 Gauge Control of Coextruded Sheet and Film

5.8.5 Coextrusion Process Control

5.9 Coextrusion Coating with Lamination

5.10 Concluding Thought

6.1 Biaxially Oriented Film

6.1.1 Introduction

6.1.2 Outline of the Tentering System Machine

6.1.3 Polymer Handling

6.1.4 The Extrusion Process

6.1.5 Filter and Die

6.1.6 The Casting Process

6.1.7 Stretching and Annealing Processes

6.1.8 Takeoff and Winding Processe

6.1.9 Process Control

6.1.10 Closing Comments

6.2 Influence of Processing Conditions on Structure and Physical Properties of Biaxially Stretched Engineering Thermoplastics

6.2.1 Chemistry of Polyesters and Its Importance in Processing

6.2.2 Solid State Phase Behavior of PET

6.2.3 PET Film Technology

6.2.4 Stress-Induced Crystallization

6.2.5 Development of Structure with Deformation

6.2.6 Dynamic and Static Mechanical Properties

6.2.7 Other Properties of Interest

Solid State Phase Behavior of PET

6.2.5.1 Stretching of PET below

6.2.5.2 Stretching of PET above

6.2.5.3 Deformation Behavior of PET in the Rubbery Region and Its Relationship to Thickness Uniformity

6.2.5.4 Structure and Morphology Developed by Biaxial Stretching of PET

3x3

3xl

6.2.5.6 Crystallinity and Thermal Properties

6.2.6.4 One-Step (Simultaneous) Biaxially Stretched Film

6.2.6.5 Two-Step Biaxially Stretched Films

6.3 Stretching Conditions, Orientation, and Physical Properties of Biaxially Oriented Film

6.3.1 Introduction

6.3.2 Outline of the Film Making Process

6.3.3 Sequential (LD . TD) Stretchin

6.3.4 General Properties of PET Film

6.3.5 Quality Improvement of PET Films

6.4 Theoretical Analysis ofthe Tentering Process

6.4.1 Introduction

6.4.2 Mathematical Model for the Extension of Thin Uneven Rubber Film

6.4.3 Numerical Analysis of Film Extension by the Finite Element Method (FEM)

7.1 Double Bubble Tubular Film Process System and Theoretical Analysis of Stress Development and Scaleup Rule

7.1.1 Introduction

7.1.2 Technical Trends and Typical Applications

7.1.3 Experimental and Theoretical Background

7.1.4 Results and Discussion

7.1.5 On Adaptability to Noncrystalline Resin (PS)

7.1.6 The Film Stretching Process and Its Physical Properties (Simultaneous versus Multistage)

7.1.7 The Heat Set Technique (Production of Shrink Film)

7.1.8 Development of Peripheral Technology for the Double Bubble Tubular BiaxialStretching Process

7.1.9 Prospective Directions of Double Bubble Tubular Biaxial Stretching

7.2 Biaxially Oriented Double BubbleTubularFilm: Process and Film Character

7.2.1 Introduction

7.2.2 Process Technologies and Structural Characteristics of Double Bubble Tubular Film

7.2.3 Final Comments.

Index