Extrusion Coating and Lamination - Fundamentals and Challenges
Extrusion Coating and Lamination - Fundamentals and Challenges
Extrusion Coating and Lamination - Fundamentals and Challenges
Molten
Polymer A
Chill roll
Substrate B (Film) A two layer film of
+
A/B structure
Molten Polymer A
Chill roll
Substrate B (Film)
Substrate C (Film)
Molten Polymer A
Substrate B (Film)
A three layer film
of B/A/C structure
Low Viscosity
5-9 in
{ Nip
0.2-0.3
sec
... like being in a plane which leaves the runway at 100 mph and
accelerates to 2000 mph in 0.3 seconds.
® Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
13
Effect of Air Gap on Neck-In
Total Neck-In (cm)
338 ºC Melt Temp.
12
0
6 8 10 12 14 16 18 20 22
Air Gap
12 MI, 0.917 Density
110 Meter/Min Coating Speed, 10 GM SQ. M. CT. WT.
® Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
14
Effect of Coating Speed on
Neck-In at Various Weights
Total Neck-In (cm)
3.5
2.5
0 50 100 150 200
Coating Speed (m/min)
318 ºC Melt Temperature
® Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
15
Coating Density vs. Resin Density
Coating Film Density (g/cc)
0.922
0.92
0.918
0.916
0.914
0.912
0.91
0.908
0.91 0.915 0.92 0.925 0.93 0.935
Initial Resin Density (g/cc)
® Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
16
Effect of Melt Temperature on Adhesion
Southwick-Perkins Bond Tester
. + Oxygen
O
COH
O
C
7
7 MI 0.917 Density
6
1
125 135 145 155 165 175
Melt Temperature ºC
® Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
27
Melt Index Change Due to Extrusion
Melt Index
5.5
4.5
5004I
4
Supplier A
3.5
Supplier B
3
2.5
2
Pellet 315 330
Extrusion Temp. ºC
® Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
28
Multiple-pass Extrusion of 7 MI LDPE and Its
Affect on Molecular Weight Distribution
Single Pass
Third Pass
Fourth Pass
14 16 18 20 22 24 26 28
Elution Volume
® Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
29
Heat Seal Strength of PE
Extrusion Coating Resins
Heat Seal Strength (lbs / in)
6 LLDPE
5.5 MI, 0.923 Density
5 LDPE
8.0 MI, 0.917 Density
4
LDPE
12 MI, 0.917 Density
3
2 LDPE
4.5 MI, 0.923 Density
1
0
95 120 145 170 195
Seal Temperature ºC
® Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
30
Moisture Vapor Transmission Rate vs. Coating
Weight
MTR (g/24 hrs/sq m at 37 ºC 90% R.H.)
40
35
0.918 Density
30
25 0.923 Density
20
15 0.930 Density
10
5
5 10 15 20 25 30 35
50
Taber Abrasion Using CS-10
Wheels W/ 1000 Gram Loads LLDPE
40 5.4 MI, 0.933 Density
LLDPE W/ Slip
5 MI, 0.921 Density
30
LLDPE
5 MI, 0.921 Density
20 OPP Film
IONOMER
10
MDPE
LDPE
0
6
LDPE 4012
5
4
LDPE 722
3
2 LDPE 4005
1
DOWLEX™ 3010 PE Resins
0
95 105 115 125 135 145
Temperature ºC LDPE 5004I
ELITE™ Enhanced
Polyethylene Resins
Low Density Polyethylene Resins
Excellent hot tack performance, low
Good performance across properties
taste and odor, and low seal
®TM Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
initiation temperature
36
Dow Products Offering
Melt Index Density
(g/10min) (g/cm3)
Dow LDPE 722 8.0 0.918
®TM Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
37
Challenges in Extrusion
Coating and Lamination
- overcome by Dow Solution Products….
Quang Vu Nguyen, PhD MBA
23rd September 2010
15 MI
ELITE™ 5815 PE Resins
0.910 g/cm3 density
25
Heat Seal Strength (N/25mm)
20
LDPE 722
15
ELITE™ 5815
10
0
90 100 110 120 130 140
30.000
Heat Seal Strength (N/25mm)
15.000
ELITE™ 5815 @ 300 ºC
10.000
ELITE™ 5815 @ 320 ºC
5.000
0.000
90 100 110 120 130 140
Puncture
180
160
140
120
100
Puncture
80
60
40
20
0
LDPE ELITE 5815
350
300
250
200
Dart
150
100
50
0
LDPE ELITE 5815
ELITETM 5815 PE Resins offer Dart Impact 3 times better than LDPE
ELITE™ 5815 PE
Resins – 330oC
Viscosity [Pa.s]
LDPE722 - 315 [°C] LDPE722 - 330 [°C] LDPEPG7008 - 315 [°C] LDPEPG7008 - 330 [°C]
ELITE5815 - 315 [°C] ELITE5815 - 330 [°C]
46
®™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
Solution to Challenge No. 2
Adhesion to OPP
(OPP film/25 µm Coating Layer)
200
Bond Strength (g/25mm)
150
100
50
0
LDPE 722 ELITE™ 5815 PE Resins
600
Bond Strength (g/25mm)
500
400
300
200
100
500
Bond Strength (g/25mm)
400
300
200
100
DR = V2/V1
• Increasing line speed
will build up stresses
in the molten web
• High stresses will
cause the curtain to
break
• That is the reason
why when LDPE is
used, the line speed
is limited
®Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
50
Solution to Challenge No. 3
Due to high tie chain concentration,
C8 solution resin can withstand
much higher stresses than LDPE
As a result, line speed can be much
higher without causing the curtain to
break.
10 16
9 14
8 12
7
10
Million MT
Million MT
6
5 8
4 6
3 4
2
2
1
0 0
2008 2009 2010 2011 2012 2013 2014 2015 2008 2009 2010 2011 2012 2013 2014 2015
100
At 325oC
Viscosity [Pa.s]
At 325oC
100 1,000
Shear Rate [1/s]
50
45
40
Answer: 74% LDPE 1 + 26% E5815
Viscosity [Pa.s]
35
30
25
100 200 300 400 500 600 700 800 900 1,0001,100
Shear Rate [1/s]
722 - 325 [°C] 5815 - 325 [°C] Blend: 722 & 5815 [0.5] D795C
LDPE 1 - 325 [°C]
5815 - 325 [°C] LDPE 1 & 5815 [0.74]
Blend: D795C
50
45
40
35
30
25
100 200 300 400 500 600 700 800 900 1,0001,100
Shear Rate [1/s]
722 - 325 [°C] 5815 - 325 [°C] Blend: 722 & 5815 [0.5] LDPE X - 325 [°C]
D795C
5815 - 325 [°C] LDPE X & 5815 [0.655]
Blend: D795C