Studies on wire coating extrusion. II. The rheology of wire coating coextrusion

An experimental and theoretical study of wire coating coextrusion through a pressure-type die was carried out. For the experimental study, the wire coating apparatus employed was the same as that described in Part I of this series (14), except for the newly constructed coextrusion die. The die was provided with three melt pressure transducers along the axial direction, which permitted us to determine the pressure gradient in the die. It was found that a reduction in pressure gradient was realized when a lower viscosity polymer was coextruded with a high viscosity polymer. The materials used for the coextrusion were combinations of low-density polyethylene, high-density polyethylene, polystyrene, and two different commercially available thermoplastic rubbers (UniRoyal TPR-1900 and Shell Kraton G 2701). The use of a high shrinking (crystalline) polymer inside a low shrinking (amorphous) polymer was found to give rise to distorted coatings (non-circular cross section of the coated wire). The interface between the coextruded layers was examined under a magnifying lens, and it was found that under certain processing conditions, the interface was highly irregular. Experimental correlations were obtained to explain the onset of an unstable interface in terms of the rheological properties of the individual components being coextruded, and of the processing variables. It was found that interfacial instability occurs when the shear stress and the viscosity ratio (also elasticity ratio) of the two components at the interface exceed certain critical values. For the theoretical study, using a power-law model, the equations of motion were solved numerically to predict the volumetric flow rate as functions of the pressure gradient in the die and the rheological properties of the polymers being coextruded. Solution of the system of equations permitted us to predict the velocity profile and shear stress distributions of two molten polymers inside a pressure-type wire coating coextrusion die. Comparisons were made between the experimental and theoretically predicted volumetric flow rates. The comparison was found to be reasonably good with certain systems. The discrepancy between the experimentally obtained and the theoretically predicted volumetric flow rates was attributed to interface migration and interfacial instability.     

Studies on structural foam processing I. The rheology of foam extrusion

An experimental study was carried out to investigate the flow behavior of gas-charged molten polymers in foam extrusion. For the study, a rectangular slit die with glass windows was constructed to permit visual observations, from the direction perpendicular to flow, of the dynamic behavior of gas bubbles when a gas-charged molten polymer flows between two parallel planes. Pictures were taken of gas bubbles in the flow channel with the aid of a camera attached to a microscope, and these were later used to determine the position at which gas bubbles start to grow. Using three melt pressure transducers mounted on the short side of the rectangular slot, pressure distributions were measured along the longitudinal centerline of the die. The polymeric materials used were high-density polyethylene and polystyrene, and the chemical blowing agents used were a proprietary hydrazide which generates nitrogen, and sodium bicarbonate which generates carbon dioxide. It was observed that the gas-charged molten polymer shows a curved pressure profile as the melt approaches the die exit, whereas the polymer without a blowing agent shows a linear pressure profile. The visual observations of the bubble growth in the flow channel, together with the pressure measurements, permitted us to determine the bubble inflation pressure, often referred to as the critical pressure for bubble inflation. It was found that the critical pressure decreases with increasing melt extrusion temperature, and increases with increasing blowing agent concentration. It was also found that the bulk viscosity of gas-charged molten polymers decreases with increasing blowing agent concentration and with increasing melt temperature. A general remark is made concerning the precaution one should take when an Instron rheometer is used for determining the bulk viscosity of gas-charged molten polymers.     

Studies on multilayer film coextrusion I. The rheology of flat film coextrusion

Multilayer flat film coextrusion was studied, both experimentally and theoretically. For the experimental study, a sheet-forming die with a feedblock was designed, and plastic films of three and five layers were coextruded. The die was provided with three pressure transducers in the axial direction in order to determine the pressure gradient in the die, allowing the determination of the reduction in pressure drop when different combinations of two polymer melts were coextruded. Polymers used for coextrusion were: (1) low density polyethylene and ethylene-vinyl acetate; (2) low density-polyethylene and high density polyethylene; (3) low density polyethylene and polystyrene. For the theoretical study, the z-component of the equations of motion for steady fully-developed flow were solved using a power law non-Newtonian model, Comparisons were made between the experimental and the theoretically predicted volumetric flow rates. Predictions of the velocity distributions, shear rate profiles, and shear stress distributions were made as functions of the processing conditions and the rheological properties of the individual polymers concerned.     

Studies on blown film extrusion. I. Experimental determination of elongational viscosity

Blown-film extrusion experiments were carried out to investigate the elongational flow behavior of viscoelastic polymer melts at different melt temperatures. Materials chosen for study were high-density polyethylene, lowdensity polyethylene, and polypropylene. In the study, isothermal blown-film extrusion experiments were carried out in which the molten blown film traveled upward through a heated chamber of about 13 in. in length maintained at the same temperature as the melt. Axial tension was measured at the take-up roller, the axial profiles of bubble diameter were determined by a photographic technique, and, from the samples collected, the variation in the film thickness along the axial direction was found. These measurements were used later to determine the elongational viscosity, using the force balance equations. It was found, in the experiment, that a careful control of the pressure difference across the thin film permitted one to maintain the bubble diameter constant, and, therefore, depending on the choice of the extrusion conditions, either a uniaxial or biaxial elongational flow was made possible. The experimental results show that, depending on the materials, elongation rate, and melt temperature tested, the elongational viscosity may decrease or increase with elongation rate, and may also stay constant independent of elongation rate. It was observed that the data of elongational viscosity obtained under uniaxial stretching in blown film extrusion is consistent with the data of elongational viscosity obtained earlier by use of the melt-spinning operation.     

The rheology and spin coating of polyimide solutions

The rheological properties of five types of concentrated polyamic acid and polyimide solutions are characterized by non-Newtonian shear viscosity η(\documentclass{article}\pagestyle{empty}\begin{document}$ {\rm \dot \gamma} $\end{document}) and primary normal stress coefficient Ψ₁(\documentclass{article}\pagestyle{empty}\begin{document}$ {\rm \dot \gamma} $\end{document}) measurements over a wide range of shear rates. Onset of non-Newtonian flow of the polyamic acid solutions was observed in the shear rate range 30 to 400s^?1 and of the fully imidized polyimide solution at below 3 × 10^?2s^?1. Significant viscoelastic properties exemplified by normal stresses were observed in all the solutions. The solution rheology results are discussed in the context of spin coating for the deposition of thin films. The relative magnitude of effects of non-Newtonian flow on the dynamics of spin coating is assessed with a Deborah number characteristic of the flow.     

Studies on the theory of single screw plasticating extrusion. Part I: A new experimental method for extrusion

An extruder specially designed for the study of the single-screw plasticating extrusion process was constructed. Its barrel is equipped with glass windows which are located on both sides of it so that the full process of plasticating extrusion, solid conveying, melting, and melt conveying, can be clearly observed and recorded with photos and video recordings through the transparent windows. The solid profile X/W, the velocity of the solid bed V_sz, the forming positions of the upper melt film and the melt pool, and the position at which the break-up of solid bed occurs, was easily determined with good accuracy. Many dynamic characters of the plasticating extrusion, such as the non-plug solid conveying, the process of the break-up of the solid bed and the disappearance of the, broken pieces of solid, were also observed in the experiments.     

The rheology and extrusion processing performance of wood/melamine composites

A modified melamine resin that exhibits both thermoplastic and thermoset behaviors was used as a matrix for wood plastic composites (WPCs). The thermoplastic melamine (TPM) resin exhibits a glass transition at approximately 34°C and continues to be thermally malleable until a crosslinking reaction develops with additional heating and an acid catalyst. Varying blends of TPM and wood flour were evaluated for their rheology and curing behavior using torque rheometry. WPC composites were manufactured with extrusion methods and final product properties determined. The torque rheometry results showed a highly dependent relationship of the curing behavior to the amount of wood flour utilized and temperature. Based upon the torque rheometry results, two extrusion platforms were developed to initiate the curing process; (1) cure within the die land and (2) post‐cure of the extrudate. The post‐cure procedure provided composites with higher mechanical properties. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 39858.     

涂层级LDPE树脂的加工性能

通过测试低密度聚乙烯（LDPE）的熔体流动速率、熔胀比、熔流比等常规物理性能及熔体黏弹性,计算评估了涂层级LDPE树脂的加工速率和缩幅;采用熔体拉伸测试和挤出复合加工实验验证了评估的准确性.经评价,预测LDPE 1C7A-1的加工速率可达400 m/min以上,试验数据也达到和超过国外对比试样.     

挤出口模设计中的流变学初步研究

对熔体在管机头、板机头以及异型材机头中的流动进行了流变学分析,指出了挤出胀大行为在各种机头中的影响作用,以及在考虑流变性能时挤出口模的设计要点。     

The impact of rheology of human fibronectin-fibrinogen solutions on fibre extrusion for tissue engineering

Fibronectin-fibrinogen composite materials form a basis for natural constructs for applications in soft tissue engineering including skin repair, blood vessel replacement and nerve regeneration. Scaleable methods for the preparation of such scaffolds are a prerequisite for their widespread use. Here, we report data on the extrusion of fibronectin-based constructs in the form of fibres.The results suggested that events occurring in the extrusion head and coagulation bath were critical in determining the ultimate mechanical strength of the extruded fibres. These events were controlled by interaction between the rheology of the dope, the geometry of the extrusion device and the operating parameters of the extrusion process. The rheology of the dope was successfully controlled by incorporation of sodium alginate, and urea was added to the formulation to produce oriented fibres. We previously reported that oriented fibronectin fibres have the capacity to induce desirable cell responses.Measurements indicated that for a given formulation, the mechanical properties and morphological features depended on the diameter of the extruded fibre, the rate of shear in the extrusion pipe and the time of exposure to it.     

Studies on multilayer film coextrusion III. The rheology of blown film coextrusion

Multilayer blown film coextrusion was studied, both experimentally and theoretically. For the experimental study, an annular die with a feed-port system was designed and multilayer blown films were produced by rotating the inner mandrel with a one horsepower variable-speed drive at speeds from nearly 2 to 6 rpm, and by inflating the tubular molten film with air. The die has 16 feed slots and melt pressure transducers are mounted along the axial direction of the outer wall of the annular flow channel. The transducers were used to determine the pressure gradient in the annular flow channel, which then permitted determination of the reduction in pressure drop when different combinations of two polymer systems were coextruded. Polymers used for b own film coextrusion were: (1) low-density polyethylene with ethylene-vinyl acetate; (2) low-density polyethylene with high-density polyethylene; (3) low-density polyethylene with polypropylene; (4) high-density polyethylene with ethylene-vinyl acetate. For the theoretical study, stratified helical flow was analyzed using a power-law non-Newtonian model. A computational procedure was developed to predict the number of layers, layer thickness, and the volumetric flow rate as functions of certain processing variables (namely, the pressure drop in the die, and the angular speed of rotation of the inner mandrel of the die) and the rheological parameters of the individual polymers concerned. Comparison was made of the theoretical prediction of volumetric flow rate with experimental ones. Some representative results are presented of the theoretically predicted axial and angular velocity distributions, shear stress profiles, and shear rate profiles.     

Shear and elongational rheology of polyethylenes with different molecular characteristics. I. Shear rheology

Four metallocene polyethylenes (PE), one conventional low density polyethylene (LDPE), and one conventional linear low density polyethylene (LLDPE) were characterized in terms of their complex viscosity, storage and loss moduli, and phase angle at different temperatures. The effects of molecular weight, breadth of molecular weight distribution, and long‐chain branching (LCB) on the shear rheological properties of PEs are studied. For the sparsely long‐chain branched metallocene PEs, LCB increases the zero‐shear viscosity. The onsets of shear thinning are shifted to lower shear rates. There is also a plateau in the phase angle, δ, for these materials. Master curves for the complex viscosity and dynamic moduli were generated for all PE samples. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Studies on blown film extrusion. III. Bubble instability

An experimental study has been carried out to investigate flow instabilities in blown film extrusion. Two types of flow instabilities were observed, depending on whether a bubble was under uniaxial or biaxial stretching. Under biaxial stretching, the phenomenon of a surface wave-type instability was observed, yielding wavy bubble shapes which very much resembled water waves at the free surface. Under uniaxial stretching, another type of instability, frequently referred to as draw resonance, was observed. It was also observed that, once draw resonance occurs, the amplitude and frequency of bubble diameter pulsing increased with stretch ratio. Quantitative information was obtained from a series of motion pictures taken of bubble diameter in both types of flow instability. It was observed further that an increase in extrusion melt temperature enhanced the severity of bubble instability.     

Finite element analysis of wire coating

A general-purpose finite element program has been used to simulate the flow of polymers through wire-coating dies. The analysis includes Newtonian and power-law fluids. The effect of normal stresses was examined through a simple viscoelastic constitutive equation, Nonisothermal wire coating was studied to obtain the temperature field within the melt. The effect of a slip condition at the solid boundaries was also examined. The determination of the coating melt free surface was carried out through an iterative procedure. The finite element solution provides details about the existence and extent of recirculation regions, about hot spots due to viscous dissipation, and also captures the stress singularities present at the impact of the melt with the wire and at the exit from the die. Pressure distribution, maximum temperature rise, haul-off wire tension, maximum wire tension, and stresses at the wire surface and die wall are also presented.     

挤出涂层级LDPE树脂1C7A-1的结构与性能

研究了涂层级低密度聚乙烯1C7A-1的相对分子质量及其分布,甲基支化度及羧基、碳碳双键含量,熔胀比及加工性能。结果表明:1C7A-1的相对分子质量及其分布为15～17、熔胀比为1.71,均与国外试样相当;甲基支化度、双键数、羰基含量适中;具有优良的高速加工性能。     

The effect of materials' rheology on process energy consumption and melt thermal quality in polymer extrusion

Polymer extrusion is an important but an energy intensive method of processing polymeric materials. The rapid increase in demand of polymeric products has forced manufactures to rethink their processing efficiencies to manufacture good quality products with low-unit-cost. Here, analyzing the operational conditions has become a key strategy to achieve both energy and thermal efficiencies simultaneously. This study aims to explore the effects of polymers' rheology on the energy consumption and melt thermal quality (ie, a thermally homogeneous melt flow in both radial and axil directions) of extruders. Six commodity grades of polymers (LDPE, LLDPE, PP, PET, PS, and PMMA) were processed at different conditions in two types of continuous screw extruders. Total power, motor power, and melt temperature profiles were analyzed in an industrial scale single-screw extruder. Moreover, the active power (AP), mass throughput, torque, and power factor were measured in a laboratory scale twin-screw extruder. The results confirmed that the specific energy consumption for both single and twin screw extruders tends to decrease with the processing speed. However, this action deteriorates the thermal stability of the melt regardless the nature of the polymer. Rheological characterization results showed that the viscosity of LDPE and PS exhibited a normal shear thinning behavior. However, PMMA presented a shear thickening behavior at moderate-to-high shear rates, indicating the possible formation of entanglements. Overall, the findings of this work confirm that the materials' rheology has an appreciable correlation with the energy consumption in polymer extrusion and also most of the findings are in agreement with the previously reported investigations. Therefore, further research should be useful for identifying possible correlations between key process parameters and hence to further understand the processing behavior for wide range of machines, polymers, and operating conditions.     

Simulation of extrusion coating by tape drawing

Neck-in and maximum stress were studied in a tape-drawing experiment using a 3.5 MI low density polyethylene at 300°C. The conditions of the experiment were designed to reproduce closely those found in extrusion coating lines. The maximum stress was found to increase roughly with the 1.6 power of the drawdown ratio and the 1.0 power of the extrusion speed over a stress range of 4 × 10³ to 5 × 10⁵ Pa produced by drawdown ratios ranging from 2 to 22 and extrusion speeds of 2.3 to 6.1 cm s^?1. The neck-in decreased weakly with drawdown ratio at low extrusion speed and with extrusion speed at constant drawdown ratio. After carefully characterizing the test resin in shear and extension, the similarities between predicted pure-shear (planar extension) transients and the tape experiments were studied. It was found that the trends, but not the magnitude of the experimental maximum stress were quite similar to the calculated longitudinal stress in pure shear. The behavior of the transverse to longitudinal stress ratio in pure shear was similar in behavior to the neck-in results, but considerable improvement was achieved by adding in a decayed stress from a simple-shear transient to simulate the conditions produced by the extrusion die. The philosophy of purposefully studying similarities between transient, pure or simple deformations and steady, complex processes is discussed.     

高速挤出涂覆专用树脂的工业开发

结合市场需求和低密度聚乙烯（LDPE）装置特点,开发了LDPE高速挤出涂覆专用树脂1C7A-1。确定了反应压力、反应温度、引发剂消耗量及链转移剂加入种类。生产的1C7A-1各项指标可满足市场需求,涂覆过程中的膜边缘稳定性得到提高,挤出复合时缩幅较小,且加工速度较高（大于280m/min）,最小涂覆厚度达到6μm,填补了国内无菌包装高速挤出涂覆树脂生产的空白。