Extrusion coating performances of iPP/LDPE blends

The performance of iPP/LDPE blends in an extrusion coating process was investigated in the terms of coating width and draw‐down ability. It is well known that iPP alone is not proper because of lower draw‐down ability with severe draw resonance in elongational flow. To obtain higher draw‐down ability, iPP was blended with LDPE. Additionally, iPPs having different molecular weight distribution (MWD) were used in this study to find out the effect of MWD of iPP on neck‐in and draw‐down ability. It was observed that iPP/LDPE blend with narrower MWD exhibits narrower coating width and higher draw‐down ability. Neck‐in and draw‐down ability were correlated with shear and elongational properties obtained by several rheological measurements. From this study, the major rheological parameters affecting extrusion performance in iPP/LDPE blends could be assessed. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

New process for producing an extrusion laminated film without any chemical primer—non anchor coating extrusion laminating process

A new process, the Non Anchor Coating Extrusion Laminating Process for producing an extrusion laminated film without any chemical primer, was investigated. Good adhesive properties were obtained by combining an ozone treatment of a molten polyethylene (LDPE) web and an activation treatment of the polyamide (ONy) substrate film. The adhesion mechanism induced by the new process was studied by FT-IR, ESCA and extraction of unreacted polyamide from the laminated samples. The peel strength between the ONy and LDPE laminated films produced with this process was greater than that for laminated film made with a conventional lamination process using anchor coating agents. A model of the adhesive mechanism is proposed. Hydrogen and covalent bonds through oxygenated functional groups are responsible for the enhanced adhesion.     

Mathematical and computational modeling of heat transfer and deformation in film blowing process

The blown‐film extrusion process was investigated both experimentally and theoretically. In experimental study, nonisothermal experiments were conducted using low‐density polyethylene. Rheological parameters were studied, considering the polymer melt as a power law fluid in nonisothermal conditions. Axial tension, bubble diameter, and film thickness at a variety of film extrusion conditions, that is, different flow rate, pressure difference across the film, and take‐up speeds were measured. In theoretical study, an analysis was employed to simulate the blown‐film extrusion process by setting up the force‐ and energy‐balance equations on the film bubble moving upward. Four nonlinear complex differential equations were integrated numerically, using an iterative backward shooting method and the fifth‐order Runge‐kutta technique. The program written, based on a mathematical model, predicts the bubble shape, temperature profile, and film thickness as a function of the distance along the machine axis. Furthermore, the model evaluates the elongational viscosity of LDPE in biaxial tension in terms of distance from die axis and take‐up speed. In this simulation, the total stress components in machine and the transverse directions were computed from the die exit up to the freeze line, the knowledge of which is necessary for evaluation of the elastic memory build up in heat‐shrinkable films. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 86: 2115–2123, 2002     

Heat sealability of laminated films with LLDPE and LDPE as the sealant materials in bar sealing application

The heat sealability of laminated films with linear low density polyethylene (LLDPE) and low density polyethylene (LDPE) as the sealant materials was investigated. A laboratory heat sealer was used to study the response of laminated films to temperature, time, and pressure. Platen temperature was confirmed as primary factor in controlling heat‐seal strength. Dwell time must be sufficiently long to bring the interfacial temperature to a desired level. When the desired heat‐seal strength has been achieved, further increase of dwell time did not improved heat‐seal strength. Platen pressure had little effect above the level required to flatten the materials for good contact. Bar sealing process window for each sample were developed. The optimum combination of platen temperature and dwell time for each laminated film can be obtained in the respective process windows. Strength of heat‐seal and its failure modes are closely related. Plateau initiation temperature closely corresponds to the final melting point of sealant materials. Relatively higher platen temperature was required to seal laminated films with lower thermal conductance. Required dwell time corresponds closely to the heat flow rate of bar sealing process. Laminated films made from extrusion lamination process provided lower level of achievable heat seal strength when compared with the laminated films made from dry‐bond lamination process. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 3736–3745, 2007     

管式法挤出涂层专用LDPE的性能及质量改进

针对管式工艺生产的挤出涂层专用低密度聚乙烯(LDPE)产品存在涂层与基材的黏结强度低、淋膜缩幅大等问题,通过与同类釜式产品的性能和结构的对比研究发现,管式产品的分子支化程度过低是造成其性能不佳的主要原因。分析了影响产品长链支化程度的工艺因素,并提出了增加产品长支链含量的方法。初步试生产表明:适当提高反应温度、降低反应压力并改变分子量调节剂的注入速度,可以有效地改善挤出涂层产品的性能。     

Validation of Double Convected Pom‐Pom model with particle image velocimetry technique

The performance of Double Convected Pom‐Pom (DCPP) model in predicting contraction flow was examined by means of particle image velocimetry (PIV) technique. Both the velocities at the centerline and the flow patterns were investigated experimentally and numerically for low density polyethylene (LDPE) and high density polyethylene (HDPE). Comparison between predicted velocity and experimental velocity showed that the DCPP model was able to quantitatively predict the velocity of HDPE in contraction flow while only qualitative agreement was observed for LDPE. It was found that for both polyethylenes the absolute velocity discrepancy increased with the rise of flow rate. The relative velocity discrepancy of both polyethylene melts did not change much when increasing the flow rate of the melts. The flow patterns matched well for LDPE, but for HDPE numerical simulation predicted recirculation at the re‐entrant corner which did not exist in experiment. POLYM. ENG. SCI., 55:1897–1905, 2015. © 2014 Society of Plastics Engineers     

Transparent low‐density polyethylene/starch nanocomposite films

Low‐density polyethylene (LDPE)/starch nanocomposite films were prepared by melt extrusion process. The first step includes the preparation of starch–clay nanocomposite by solution intercalation method. The resultant product was then melt mixed with the main matrix, which is LDPE. Maleic anhydride‐grafted polyethylene (MAgPE), produced by reactive extrusion, was used as a compatibilizer between starch and LDPE phases. The effects of using compatibilizer, clay, and plasticizers on physico‐mechanical properties were investigated. The results indicated that the initial intercalation reaction of clay layers with starch molecules, the conversion of starch into thermoplastic starch (TPS) by plasticizers, and using MAgPE as a compatibilizer provided uniform distribution of both starch particles and clay layers, without any need of alkyl ammonium treatment, in LDPE matrix. The nanocomposite films exhibited better tensile properties compared to clay‐free ones. In addition, the transparency of LDPE film did not significantly change in the presence of TPS and clay particles. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Scratch behavior of extrusion and adhesive laminated multilayer food packaging films

Scratch‐induced puncture damages on adhesive and extrusion laminated multilayer food packaging films were investigated. Films were tested using a modified standardized linearly increasing load scratch test methodology, ASTM D7027‐05/ISO 19252:2008, which has successfully demonstrated an ability to correlate damages observed in field use of packaging films to laboratory findings. Samples were cross‐sectioned to view the evolution of damage in a layer‐by‐layer fashion to determine any potential weak‐link in the laminate. It was observed that the extrusion laminated film showed both superior scratch performance and superior layer adhesion with increasing scratch load, particularly upon severe film deformation. The extrusion lamination process may be used to produce strong, scratch‐resistant packaging films without the need for additional adhesive layers and the associated health and environmental concerns. Usefulness of the standardized scratch testing for evaluating performance of food packaging films and laminates is discussed. POLYM. ENG. SCI., 54:71–77, 2014. © 2013 Society of Plastics Engineers     

Blending of low‐density polyethylene with vanillin for improved barrier and aroma‐releasing properties in food packaging

Modification of low‐density polyethylene (LDPE) with vanillin to obtain flavored packaging film with improved gas barrier and flavor‐releasing properties has been studied. The modification of LDPE with vanillin was monitored by Fourier transform infrared spectroscopy, wherein the appearance of new peaks at 1704.7, 1673.6, and 1597.2 cm^?1 indicates the incorporation of vanillin into LDPE matrix. Films of uniform thickness were obtained by the extrusion of modified LDPE. Modified LDPE was found to have significantly higher gas barrier properties and grease resistance. Sensory quality of food products viz, doodhpeda (milk‐based solid soft sweet), biscuit, and skimmed milk powder packed in LDPE‐vanillin film showed that the doodhpeda sample had clearly perceptible vanilla aroma, whereas biscuit had marginal aroma and skimmed milk powder did not have noticeable aroma. When viewed in the light of imparting desirable vanilla aroma, results of the study indicated that LDPE‐vanillin film has better prospects as a packaging material for solid sweets with considerable fat content when stored under ambient conditions. The release of vanilla aroma was further confirmed by gas chromatography–mass spectrometery analysis. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Degradation of low density polyethylene during extrusion. IV. Off‐flavor compounds in extruded films of stabilized LDPE

This study was aimed at finding a correlation between the experienced off‐flavor in packed foods and the presence of specific degradation products in LDPE packaging films. The possibility to trap degradation products by chemical reactions with scavengers, i.e., a zeolite additive or antioxidants, was investigated This would prevent degradation products from migrating to the polymer film surface and further into food in contact with the film. It was found that off‐flavor noted in water packed in LDPE films depended on extrusion temperature and exposure time for the melt to oxygen, that is, the parameters that influence the contents of oxidation products that are able to migrate from the polymer film. It was also found that adsorption of oxidative degradation products in a zeolite additive or protection of LDPE by using antioxidants could prevent off‐flavor in the packed product (water). However, the antioxidant should be selected with regard to extrusion temperature because thermal instability in the additive might jeopardize the intended effect. Multifunctional antioxidants seem to provide improved protection, the most effective one evaluated in this work being Irganox E201, i.e., vitamin E. Concentrations of oxidized degradation products are well correlated to the perceived off‐flavor in the packed water. The highest correlation between off‐flavor and oxidized components was found for ketones in the range of C₇ to C₉ and aldehydes in the range of C₆ to C₉. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 95: 583–595, 2005     

Numerical simulation of polymer foaming process in extrusion flow

Computer simulations of polymer foaming processes in extrusion flow have been carried out in order to improve current understanding of viscoelasticity and bubble growth effects on die-swelling in the production of polymer foam. The linear and non-linear viscoelastic materials functions of a commercial low density polyethylene (LDPE) melt have been extracted by fitting its rheometric data with constitutive models including a simple viscoelastic model (SVM), the exponential Phan-Thien–Tanner (EPTT) model and the double convected pom–pom (DCPP) model. Simulations of LDPE melt under extrusion flow without foaming show that the predictions of the die-swell by the SVM are in reasonably good agreement with the results obtained from the EPTT and DCPP models. By comparison of the simulation results of LDPE foaming in extrusion flow using the Bird–Carreau model and the SVM, a cooperative effect of polymer viscoelasticity and bubble growth on the die-swell has been quantified. The numerical results also show that the density of polymeric foam decreases significantly with the increasing concentration of foaming agent, and that the combination of the SVM and bubble growth model can account for some essential physics of polymer foaming process in extrusion flow.     

Molecular,rheological, and crystalline properties of low‐density polyethylene in blown film extrusion

The molecular weight and its distribution, degree of long chain branching and cooling rate strongly influence crystallinity during processing, which in turn determines the processability and the ultimate properties of the blown film. Generally a decrease in the number of branches and molecular weight of the polymer and the cooling rate results in an increase of the crystallinity. Length of the main chain and extent of branching in low‐density polyethylene (LDPE) are also factors that affect melt rheology and film crystallinity. Long chain branched polyethylene is suitable in the blown film process due to its better melt strength for bubble stability. The objective of this article is to describe the effect of molecular properties (e.g. molecular weight and its distribution, degree of long chain branching etc) of LDPE on film crystallinity at different cooling rates of blown film extrusion. Two different grades of LDPE were selected to investigate molecular characteristics, crystallinity, and rheology. The resins were processed in a blown film extrusion pilot plant using four different cooling rates. Molecular, rheological, and crystalline properties of the resins were key parameters considered in this study. POLYM. ENG. SCI., 47:1983–1991, 2007. © 2007 Society of Plastics Engineers     

Structural changes of PVC in PVC/LDPE melt‐blends: Effects of LDPE content and number of extrusions

This paper investigates the structural changes of polyvinyl chloride (PVC) in melt‐blends of a low‐density polyethylene (LDPE) and polyvinyl chloride (PVC), and the effects of LDPE content and number of extrusion passes. These effects were examined in terms of changes in weight average molecular weight and number average molecular weight, polyene and carbonyl indices, color changes of the blend, and the variations in glass transition and decomposition temperatures. It was found that loading LDPE into PVC led to the formation of short‐chain LDPE grafted PVC (s‐LDPE‐g‐PVC) copolymers, via a macro‐radical cross‐recombination reaction, which had greater weight average molecular weight with unchanged number average molecular weight, increased decomposition temperature, lower glass transition temperature, as compared to the pure PVC sample. The dehydrochlorination reaction of PVC was suppressed by the macro‐radical cross‐recombination reaction with addition of LDPE, the effect being more pronounced at 13.0 wt% LDPE. For a given LDPE content, the macro‐radical cross‐recombination and dehydrochlorination reactions competed with one another, thus causing the increases in molecular weight average and molecular weight number up to the 4th extrusion pass. At the 5th extrusion pass, the dehydrochlorination reaction was predominant owing to a depletion of LDPE content to be grafted onto PVC molecular chains. The glass transition and decomposition temperature decreased with increasing number of extrusion passes. Polym. Eng. Sci. 44:487–495, 2004. © 2004 Society of Plastics Engineers.     

LDPE／PA6共混阻透薄膜的研制

将LDPE、PA6和PE-g-MAH等混合后加入单螺杆挤出机内,经熔融挤出吹塑制成LDPE/PA6共混阻透薄膜。通过考察成型工艺条件及PA6和PE-g-MAH的用量对薄膜阻透性能和力学性能的影响,确定了共混配方和薄膜制备工艺,阻透薄膜的阻透性能与纯LDPE薄膜相比提高了10倍以上。     

Degradation of low density polyethylene during extrusion. III. Volatile compounds in extruded films creating off‐flavor

This study was aimed at finding a correlation between the experienced off‐flavor in packaged foods and the presence of specific degradation products in PE packaging films. The possibility to trap degradation products by chemical reactions with scavengers, that is, zeolites and maleic anhydride grafted LLDPE, were investigated. This trapping would prevent the degradation products from migrating to the polymer film surface and further into food in contact with the film. This work concludes that off‐flavor in water packed in LDPE‐films depends on extrusion temperature and the content of oxidation products in the polymer film. At lower extrusion temperatures, reactive additives to the LDPE material could control the release of off‐flavor giving components. Adsorbents, such as zeolites, which are able to adsorb degradation products, are effective also at higher extrusion temperatures. The amount of oxidized degradation products in the films correlated well to the perceived off‐flavor in the packed water. The presence of aldehydes and ketones have a clear impact on the off‐flavor. The best correlation between off‐flavor and oxidized components were found for C₇? C₉ ketones, and aldehydes in the range of C₅ to C₈. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 95: 847–858, 2005     

Influence of molecular architecture and melt rheological characteristic on the optical properties of LDPE blown films

A systematic investigation on the origin of the haze of LDPE blown films was conducted, aiming to correlate the film haze with the molecular architecture and melt rheological properties. First of all, the haze measurement indicated that the surface haze, rather than the bulk haze, is the dominating factor for the total haze of the investigated films. No spherulitic crystals or other superstructures were observed for the LDPE blown films, implying that the crystallites formed in the film-blowing process are too small to be responsible for the optical haze. Rheological study revealed that the surface roughness was originated from the irregular flow of LDPE melt during the extrusion process. NMR, GPC and parallel-plate rheology were applied to study the molecular architecture of the LDPE resins. It was found that the LDPE sample with higher haze value exhibits distinctly larger portion of higher molecular weight component, broader molar mass distribution, significantly higher side chain branch density.     

Three‐dimensional simulation on multilayer parison shape at pinch‐off stage in extrusion blow molding

We tried to predict the multilayer parison shape at pinch‐off stage in extrusion blow molding by nonisothermal and purely viscous non‐Newtonian flow simulation using the finite element method (FEM). We assumed the parison deformation as a flow problem. The Carreau model was used as the constitutive equation and FEM was used for calculation method. Multilayer parison used in this simulation was composed of high‐density polyethylene (HDPE) as inner and outer layers and low‐density polyethylene (LDPE) of which viscosity is five times lower than HDPE as a middle layer. We discussed multilayer parison shape in pinch‐off region. The results obtained are as follows; the parison shape of each layer was clearly visible in the pinch‐off during the mold closing. In addition, the distribution of parison thickness ratios for each layer was located for a large deformation near the pinch‐off region. The melt viscosity for each layer has an influence on the melt flow in the pinch‐off region. In a comparison with an experimental data of parison thickness ratios, the simulation results are larger than the experimental data. These simulation results obtained are in good agreement with the experimental data in consideration of the standard deviations. POLYM. ENG. SCI., 2010. © 2010 Society of Plastics Engineers     

Foam extrusion of LDPE with solid phase CO2 as blowing agent

Physical foaming usually requires special metering equipment to inject the blowing agent at high pressures. In this study, low density polyethylene (LDPE) was foamed in the extrusion process using dry ice as physical blowing agent. The blowing agent was metered in form of pellets over the hopper. To determine relevant process parameters and improve the understanding of the process a melting model is applied. The influence of the formation of a melt film and melt pool on the dissolution of the blowing agent is discussed. The theoretical considerations are validated in a design of experiment study. As a result, the efficiency of the process is especially affected by the throughput rate, granules temperature, and blowing agent concentration. Further varied parameters are the barrel temperature in the melting zone and diameter of the dry ice pellets. Fast melting and pressure build‐up were shown to reduce blowing agent losses. POLYM. ENG. SCI., 55:2821–2828, 2015. © 2015 Society of Plastics Engineers     

Use of silica from rice husk ash as an antiblocking agent in low‐density polyethylene film

In packaging applications, blocking is always found in low‐density polyethylene (LDPE) films. Practically, such problems can be solved by incorporation of antiblocking agents, for example, silica and talc. The objective of this research was to explore the possibility of using silica from rice husk ash (RHA silica) as an antiblocking agent in LDPE film. Properties of RHA silica were compared with commercial silica, Sylo‐1. The appropriate amount of silica to be used as an antiblocking agent in LDPE film was also investigated. The results indicate that RHA silica has a smaller particle size and a higher specific surface area but a higher bulk density than those of Sylo‐1 silica. In the plastic film industry, 500–1000 ppm of silica is added in LDPE films as an antiblocking agent. It was also found that LDPE film with 2000–3000 ppm RHA silica showed similar properties to LDPE film filled with commercial silica in terms of its blocking behavior, mechanical strength, and film clarity. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 848–852, 2003     

LDPE composite films incorporating ceramic powder emitting far‐infrared radiation for advanced food‐packaging applications

A ceramic powder that emits far‐infrared radiation (FIR) was incorporated into low‐density polyethylene (LDPE) via melt‐compounding and subsequent melt‐extrusion processes. To investigate the feasibility of as‐prepared LDPE/FIR composite films for use in packaging applications, the composite films were characterized using Fourier transform infrared spectroscopy, X‐ray diffraction, scanning electron microscopy, thermogravimetric analysis, differential scanning calorimetry, FIR emissivity and emissive power, antimicrobial activity assays, and storage tests. The physical properties and antimicrobial activities of the composite films were found to strongly correlate with the changes in the chemical and morphological structures that originate from different contents of FIR ceramic powder. A higher content of FIR ceramic powder in the LDPE/FIR composite film provided increased FIR emissivity and emission power of the composite and resulted in good antimicrobial activity. Storage tests also showed that incorporation of FIR ceramic powder into LDPE film was an effective method for maintaining the freshness of lettuce. Furthermore, the incorporation of FIR ceramic powder into LDPE films induced higher thermal stability and crystallinity and enhanced their barrier properties, which suggest these LDPE/FIR composite films are potential candidates for advanced packaging materials for the food and medical industries. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43102.