Internally Deckled Coating Dies Resin Characteristics and - PowerPoint PPT Presentation

Internally Deckled Coating Dies Resin Characteristics and Interaction with Die Design Session 4.1 Paper 7724 Gary Oliver Cloeren Incorporated Orange, TX USA

Polymers Evaluated Sample- MFI G' (G prime) ZSV (Zero Shear viscosity) number MFI Density Polymer Type (g/10min) Pa Pa*s 1 5.2 .940 Ionomer 5.1 100.7 6938 2 14 .950 Ionomer 17.1 133.3 2035 3 10 .930 Acid Co-Polymer 10.7 91.9 2861 4 5.1 .923 LDPE 4.9 96.7 6595 5 7 .917 LDPE 6.9 118.2 5127 6 8 .918 LDPE 7.8 116.9 4608 8 16 .923 LDPE 4.5 102.6 7914 9 16 .917 LDPE 15.3 96.4 1720 10 37 MFR .906 HOPP nr nr nr 11 8.5 .943 HDPE nr nr nr nr = no usable results from resin testing

Deckle Adjustment for Edge Bead Reduction Plug Setting Relative to Blade & Rod Setting

LIP LAND LENGTHS EVALUATED Various Lip Lands Removable Lip Extrusion Coating Die

Deckle Adjustment for Edge Bead Reduction 2½ Plug Setting - 1¼ Blade Setting

Deckle Adjustment for Edge Bead Reduction 2 Plug Setting - 1 Blade Setting “Texas 2 Step”

Die Temp: 307 ° C Polymer: Sample 6 Melt Temp: 310 ° C Line Speed: 122 M/min Target Coating Weight or Thickness: 38µ Air Gap: 150mm Plug Blade 3.2mm 6.4mm 9.5mm 12.7mm 15.9mm 19mm 22.2mm 25.4mm 28.6mm 31.8mm 34.9mm 0 0 86.36 66.04 55.88 48.26 43.18 40.64 38.10 86.36 ½ 0 88.90 68.58 55.88 48.26 45.72 43.18 40.64 88.90 1 0 78.74 60.96 53.34 45.72 43.18 40.64 38.10 78.74 1½ ½ 71.12 58.42 48.26 43.18 40.64 38.10 35.56 71.12 1¾ ¾ 60.96 53.34 48.26 45.72 43.18 40.64 38.10 60.96 2 1¼ 30.48 35.56 38.10 35.56 35.56 35.56 38.10 30.48 2½ 1¼ 30.48 33.02 38.10 38.10 38.10 38.10 38.10 30.48 2½ 1½ 20.32 20.32 25.40 33.02 38.10 38.10 38.10 20.32 3 ¾ 3 1 3 1¼ 3½ 1 3½ 1¼ 3½ 1½

Edge Bead Reduction Trial Results Sample 1 MI=5.2 G’=100.7 Deckle Settings Plug-Blade 0-0 ½-½ 1-½ 1-1 1 ½-1 2-1 2 ¼-1 ¼ 2 ¼-1 ½ 2 ½-1 ½

Edge Bead Reduction Trial Results Sample 2 MI=17 G’=133.3 Deckle Settings Plug-Blade 0-0 0-½ 0-1 ½-½ 1-½ 1-1 ½-1 2-1 2 ¼-1 ¼ 2 ¼-1 ½ 2 ½-1 ½ 2 ¾-1 ¾ 3-2 2-½ 3-½

Edge Bead Reduction Trial Results Sample 3 MI=10 G’=91.9 Deckle Settings Plug-Blade 0-0 ½-½ 1-½ 1-1 1 ½-1 2-1 2 ¼-1 ¼ 2 ½-1 ½

Edge Bead Reduction Trial Results Sample 4 MI=5.1 G’=96.7 11

Edge Bead Reduction Trial Results Sample 5 MI=7 G’=118.2

Edge Bead Reduction Trial Results Sample 6 MI= 8 G’=116.9 Deckle Settings Plug-Blade

Edge Bead Reduction Trial Results Sample 8 MI=5.2 G’=102.6 Deckle Settings Plug-Blade

Edge Bead Reduction Trial Results Sample 9 MI=16 G’=96.4

Lip Land Trials 25 gms/m 2 • Coat Weight • Line Speed variable 90 – 305 m/minute • Lip Gap Constant 0.6mm • Lip Land variable 0 – 25.4mm • Five different polymers

LIP LAND LENGTHS EVALUATED 25.4 mm

LIP LAND LENGTHS EVALUATED 12.7 mm

6.35 mm LIP LAND LENGTHS EVALUATED

0 mm LIP LAND LENGTHS EVALUATED

Extrusion Coating Polymers Evaluated • Sample 4 5.0 MFI .923 density LDPE G’ 96.7 • Sample 5 7.0 MFI .917 density LDPE G’ 118.2 • Sample 9 16 MFI .917 density LDPE G’ 96.4 • Sample 1035 MFR .906 density HOPP nr • Sample 118.5 MFI .943 density HDPE nr nr – no reliable reading

Lip Land Evaluation Sample 4 5.1 MFI G’=96.7 Neckin Sample 4 60 55 Neckin mm Land Length 0 mm Land Length 6.35 mm 50 Land Length 12.7 mm Land Length 25.4 mm 45 40 35 91.4 152.4 213.4 274.3 304.8 Line Speed m/min

Lip Land Evaluation Sample 5 – LDPE 7MFI G’=118.2 Neckin Sample 5 60 55 Neckin in mm Land Length 0 mm 50 Land Length 6.35 mm Land Length 12.7 mm 45 Land Length 25.4 mm 40 35 91.4 152.4 213.4 274.3 304.8 Line Speed m/min

Lip Land Evaluation Sample 9 - LDPE 16 MFI G’=96.4 Neckin Sample 9 60 55 Neckin in mm Land Length 0 mm 50 Land Length 6.35 mm Land Length 12.7 mm Land Length 25.4 mm 45 40 35 91.4 152.4 213.4 274.3 304.8 Line Speed m/min

Lip Land Evaluation Sample 10 37 MFR .906 HOPP Neckin Sample 10 162 152 142 Neckin in mm 132 Land Length 0 mm Land Length 6.35 mm 122 Land Length 12.7 mm 112 Land Length 25.4 mm 102 92 82 72 91.4 152.4 213.4 274.3 304.8 Line Speed m/min

Lip Land Evaluation Sample 11 8.5 MFI .943 HDPE Neckin Sample 11 162 152 142 Neckin in mm 132 Land Length 0 mm Land Length 6.35 mm 122 Land Length 12.7 mm 112 Land Length 25.4 mm 102 92 82 72 91.4 152.4 213.4 274.3 304.8 Line Speed m/min

Resin Charactistics vs. Edge Bead 27 Resin Characteristics and Die Design - Oliver

Summary • Samples examined with various viscoelastic properties • Edge Bead Reduction compared to viscoelastic properties • Die land length examined compared to viscoelastic properties • Few correlations • Work continues

Special Thanks • Otto Plassmann - INEOS Köln GmbH • Jim Cooper - Dow Plastics • Kelly Frey - CP Chemicals • Gary Jerdee - CP Chemicals • Erkki Laiho - Borealis Group • Scott Marks - DuPont 29 Resin Characteristics and Die Design - Oliver