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Extrusion lamination is one of the techniques used for laminating different materials, and is widely used as the
manufacturing process for packaging films for products such as foods, cosmetics, and pharmaceutical products
in order to obtain improved film properties such as gas barrier, heat sealing, and film strength.
Autoclave-type high-pressure low-density polyethylene (PE-HPLD) is generally used in extrusion lamination
applications because of its good neck-in property. Recently, however, the packaging industry has desired reductions in the volume of materials and high-speed processing. Therefore, plastic resins with good draw-down properties are needed. Sumitomo Chemical Co., Ltd. has developed a tubular-type PE-HPLD which exhibits a good
balance of neck-in and draw-down properties, although neck-in and draw-down properties have a trade-off relation.
In this article we investigated the effects of shapes of deckles, and setting positions of deckles and rods on
extrusion processing properties. As a result, we made their relations clear.
Furthermore, we also carried out a viscoelastic simulation of the extrusion lamination process using computer
aided engineering developed by Sumitomo Chemical Co., Ltd. The simulation could predict the neck-in phenomenon and thickness distribution for extruded PE-HPLD.
This paper is translated from R&D Report, SUMITOMO KAGAKU, vol. 2009-I.
Introduction
yen 1).
can be obtained.
Polyethylene (PE)
PE ( (CH2 CH2)
) is produced by polymeriz-
lated by JIS.)
2. PE Market
According to the statistics released by the Japan
Association1),
polymerization.
PE is the most
Petrochemical Industry
62kt
Blow
3%
94kt
Injection
5%
Cable
5%
Fig. 1
Pipe
1%
Craft paper
method.
Board paper
0.8
Plastic
packaging
Others
17%
Relative height
Film
52%
0.6
AC Type
0.4
TB Type
0.2
0
2
log Mw
Fig. 2
type.
ecular structure.
film decreases.
of PE.
Extrusion Lamination
1. Definition of Lamination
up for.
following features:
Paper :
Al :
ONy :
Die
Web
Chill roll
Air gap
Air gap, L
Substrate
Neck-in, NI
Web width, WW
Nip roll
Fig. 4
tom end of the die and the laminating part). Edge beads
can be removed by trimming or the height of the edge
beads can be flattened. It is not desirable to trim edge
beads to a great extent, as this is wastage. Edge beads
Drier
Die
Product
Substrate
Chilled roll
Lamination part
Fig. 3
Coater of AC agent
required.
Draw-down properties can be evaluated by the max-
properties.
3. Recent Efforts
levels 12).
ing to improve film thickness and processing stability when increasing take-up velocities.
2. Processing Conditions
parison.
actual examples.
Lamination Processability
(b)).
Die
Die
Upper Deckle
Neck-in
Thickness of
extruded PE
Trimming width
(Edge bead)
PE layer
100
Thickness(m)
Rod
Substrate(ONy)
120
Lower Deckle
Rod
Fig. 5
Polyethylene grade :
AC-1
TB-1
Upper Deckle
Melt PE
Lower Deckle
80
60
40
20
0
250 200 150 100
50
50
100
150
200
250
(a)
Fig. 7
(b)
R20
R=20
Upper Deckle
R10
R90
R=90-10
Lower Deckle
R5
x
Fig. 6
R130
R=130-5
Rod
By using the optimum deckle shape under the optimum processing conditions (the appropriate take-up
velocity and resin temperature), a completely flat surface can be obtained in the final product.
oped a TB-type PE-HPLD grade which is particularly suitable for extrusion lamination (TB-New). In this
AC-1
120
Thickness(m)
100
80
60
Deckle positions:
x= 0, y= 0
x= 0, y=20
x= 0, y=30
x= 0, y=50
40
20
0
250 200 150 100
50
100
150
200
250
Fig. 8
It is obvious that the TB-New grade has significantly improved neck-in properties compared to conventional TB-type PE-HPLD (TB-1). However,
compared to AC-type PE-HPLD (AC-1), it has a slightly larger neck-in value. The neck-in value can be
decreased by reducing the air gap as shown in Table
1. Since the air gap of a commonly used monolayer
AC-1
Thickness(m)
120
Deckle type:
R=20
R=90 -10
R=130 -5
100
80
Table 1
60
40
20
0
250 200 150 100
50
50
100
150
200
Grade
AC
AC-1
250
Fig. 9
Type
TB
TB-New
TB-1
Air gap(*)
(mm)
(mm)
160
35
300
160
45
> 400
190
56
> 400
220
68
> 400
160
63
> 400
Processing Simulation
will be introduced.
processing using high density polyethylene. Subsequently, Satoh et al.19) conducted conventional pseudo-three-dimensional calculations, and confirmed that
TB-New
Thickness (m)
60
Deckle positions:
x=0, y=0
x=0, y=30
x=0, y=50
50
40
three-dimensional calculations.
In this chapter, simulations using our proprietary
PE-HPLD for extrusion lamination processing will be
30
20
10
0
250 200 150 100
50
50
100
150
200
250
into the effects of resin types and processing conditions on neck-in and edge beads. In addition, the
mechanisms by which neck-in occurs were also inves-
Fig. 10
Table 2
Effects of deckle positions (x, y) on edge oscillation and edge breaking of TB-New
tigated.
Deckle positions
x
mm
30
30
30
50
50
mm
30
50
30
50
30
50
Edge oscillation
mm
25
10
27
41
38
Edge breaking(*)
()
Phan-Thien/Tanner 20)
was used
for the fluid model. Also, the Arrhenius law was adopt-
Fig. 11
160
140
100
80
Simulation
160mm
190mm
220mm
Experiment
AC-1
TB-New
TB-1
Experiment
160mm
190mm
220mm
200
160
120
60
80
80
Experiment
AC-1
TB-New
TB-1
60
40
20
120
Simulation
AC-1
TB-New
TB-1
Simulation
AC-1
TB-New
TB-1
100
0
0
100
150
200
250
Fig. 13
40
50
40
20
(a)
(b)
0
100
150
200
250
300
150
200
250
300
Width (mm)
Fig. 12
140
Simulation
AC-1
TB-New
TB-1
120
Neck-in (mm)
100
Experiment
AC-1
TB-New
TB-1
80
60
40
20
0
0
50
100
150
200
250
Fig. 14
tion while the edge part undergoes uniaxial elongational deformation. Numerous reports that support
Air gap
L
Simulation
Standard
x=0, y=30
x=0, y=50
x=50, y=50
x=50, y=50 - 2
Thickness(m)
80
60
Planar
Uniaxial
Fig. 16
Experiment
x=0, y=0
x=0, y=30
x=0, y=50
x=50, y=50
40
20
(Eq. 1)
Where, F represents the tension along web edge,
0
0
50
100
150
200
250
Width(mm)
Fig. 15
(Eq. 2)
(4) Mechanisms of the Neck-in Phenomenon
In order to clarify the mechanisms of the neck-in
phenomenon, the flow conditions in the air gap were
Here,
Py
Ux
represents
140
L : 220mm
AC-1
TB-New
TB-1
120
(Eq. 3)
100
Neck-in (mm)
L : 160mm
80
L : 120mm
60
40
20
0
1.00
1.05
1.10
1.15
1.20
Fig. 18
from the simulation into Eq. 3 and numerical integration. As shown in Fig. 17, the estimated values of
the neck-in model were quite consistent with the sim-
their validity.
Conclusion
160
140
100
80
Simulation
160mm
190mm
220mm
Neck-in model
AC-1
TB-New
TB-1
Neck-in model
160mm
190mm
220mm
200
160
120
60
80
120
Simulation
AC-1
TB-New
TB-1
40
40
20
(a)
References
(b)
0
100
150
200
250
300
150
200
250
300
Width (mm)
(2008).
Fig. 17
P.
Fig. 18 shows
P/
U >. <
P/
10
1998, p.100.
12) K. Fukano, Convertech, 22 (12), 30 (1994).
13) T. Kanai, and A. Funaki, Seni Gakkaishi, 42, 31
(1986).
14) S. DHalewyu, J. F. Agassant, and Y. Demay, Polym.
Eng. Sci., 30, 335 (1990).
15) P. Barq, J. M. Haudin, and J. F. Agassant, Intern.
Polym. Processing, 12, 334 (1992).
16) S. Smith, and D. Stolle, Polym. Eng. Sci., 40, 1870
(2000).
17) C. Sollogoub, Y. Demay, and J. F. Agassant, Intern.
Polym. Processing, 18, 80 (2003).
18) K. Sakaki, R. Katsumoto, T. Kajiwara, and K.
PROFILE
Makoto M ORIKAWA
Seiji S HIROMOTO
Yasushi M ASUTANI
Sumitomo Chemical Co., Ltd.
Petrochemicals Research Laboratory
11