Evaluation of melt flow as a measure of low density polyethylene processability into blown films

Melt capillary flow and extrudate swelling for low density polyethylenes (LDPE), differing in ease of heavy-duty, blownfilm extrusion, have been employed as processability criteria. LDPE of good processability is characterized by a unique combination of melt fluidity, temperature, shear rate dependence and melt elasticity. These characteristics of flow are correlated with LDPE film blowing process variables such as maximum take-up speed, film thickness scatter, and extruder temperatures profile. Intuitively, these melt flow criteria should be extended to Trouton's viscosity and the tensile strength of the melt. The limited development of the elongation viscometry techniques, however, has limited their application.     

Influence of low density polyethylene quality on extrusion coating processability

In order to obtain explicit information about the influence of different low density polyethylene (LDPE) quality parameters on extrusion coating processability, a test run was made with an autoclave reactor and the products were investigated. All the grades manufactured had melt indices (MI), densities, molecular weight distributions (MWD), and degrees of long chain branching(LCB) typical of commercial extrusion coating grades. The processability characteristics studied were maximum line speed and neck-in. The influence of MI, density, and extrusion melt temperature were systematically investigated. It was found that the maximum line speed rose with increasing MI, density, and extrusion melt temperature, and that an increasing extrusion melt temperature led to a growing difference between the maximum line speed at a constant coating thickness and the maximum line speed at a constant screw speed. Neck-in was found to increase with increasing MI, increasing density, and increasing coating thickness. These effects were more pronounced at higher extrusion melt temperatures. When using the extrusion temperature needed to achieve a certain line speed for each grade, the influence of MI on neck-in was practically non-existent.     

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.     

Effect of propylation of starch with different degrees of substitution on the properties and characteristics of starch‐low density polyethylene blend films

Corn starch was modified by propylation and degree of substitution (DS) of four starch modifications were 0.61, 1.56, 2.27, and 2.51. Different films were prepared by blending native and propylated starch with low‐density polyethylene (LDPE). The mechanical properties, thermal properties, water absorption capacity, and biodegradability of the blend films varied with the quantity of starch as well as DS. Tensile strength, elongation, and melt flow index of propylated starch blend films were higher compared to the corresponding native starch blend film. These properties improved with increase in DS from 1.56 to 2.51. Propylated starch blend films were found thermally stable than native starch blend films. There was a decrease in water absorption capacity for the films containing propylated starch at high DS. Enzymatic and soil burial degradation results showed that biodegradability of starch‐LDPE films increased with the increase in the starch concentration but it decreased with increase in the DS. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011.     

燕化管式法LDPE装置薄膜级产品性能及应用

以北京燕化石油化工股份有限公司200kt／a管式法低密度聚乙烯(LDPE)装置产品的熔体流动指数范围分类,分析了主要薄膜级产品的分子链结构,研究了薄膜级树脂及其薄膜的力学和老化等性能．并与市场上常用的国内外同类产品进行了对比。结果表明,管式法LDPE薄膜级产品各具特色,如LD104透明性好。乙烯一乙酸乙烯共聚物产品的耐热氧化性能和LD165的光稳定性能优良。     

Rheological and mechanical properties of poly (ethylene acrylic acid) and low density polyethylene blends

Rheological properties of poly (ethylene‐acrylic acid) (PEA) and low density poly ethylene (LDPE) blends having varied amounts of LDPE from 0 to 100% have been evaluated at different temperatures (115, 120, and 130°C) and shear rates (61.33–613.30 s^?1) using a Monsanto processability tester. A reduction in the melt viscosity of the PEA/LDPE blends was noticed with increasing the shear rate. The observed positive deviation in the experimental melt viscosities of the blends is an indication of the synergy present in the blends during melt processing. The activation energy (E_a) of flow calculated using Arrhenius relation for PEA, LDPE, and their respective blends lies in the range 29.98–40.56 kJ mol^?1. The experimental activation energy of flow of the blends was higher than that obtained from the additivity rule. Highest activation energy was noticed for the blends containing 60–80% by weight of LDPE in PEA/LDPE blends, which is an indication for the miscibility of the blends at these ratios. The physicomechanical properties such as density, tensile behavior, tear strength, and hardness (Shore A) of PEA, LDPE, and their blends have been evaluated as a function of varying amounts of LDPE. The obtained physicomechanical properties of the PEA/LDPE blends lie in between that of pure polymers. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Rheological properties of blown film low-density polyethylene resins

Three blown-film-grade low-density-polyethylene (LDPE) resins were studied using different rheological techniques. Eccentric rotating disks (ERD), cone-plate viscometry, capillary rheometry, annular die extrusion, and non-isothermal stretching of a filament were used. The viscoelasticity of the melts was found to play a dominant role in the observed behavior. Extrudate appearance in annular flow, melt strength, and extensibility are affected by melt elasticity. A correlation was found between the maximum draw ratio of a filament stretched under non-isothermal conditions and minimum film thickness.     

Elongational flow properties of low-density polyethylene and linear low-density polyethylene from nonisothermal melt spinning experiments

Low-density polyethylene (LDPE) and also linear low-density polyethylene (LLDPE) resins can be characterized by the degree of strain hardening and down-gaging during elongation. A new method for the determination of the apparent elongational flow characteristics is presented. In a small scale apparatus, a molten monofilament is stretched under nonisothermal conditions similar to those found in tubular film extrusion. Measurement of resistance to elongational flow and apparent elongational strain rates permit the comparison of the process-ability of different resins under specified conditions. The effect of melt temperature and extension ratio are examined. The importance of the molecular structure of both LDPE and LLDPE resins on these properties is also outlined.     

Studies on fiber formation of thermotropic copolyesters

Thermotropic copolyesters PET/60 PHB and PET/80 PHB fibers are melt spun at different extrusion temperatures and at different draw-down ratios. The flow behavior of PET/60 PHB is studied at different temperatures and shear rates. The melt of (PET/60 PHB) at temperatures above 265°C exhibit low viscosity and low activation energy of flow. The modulus and strength for both PET/60 PHB and PET/80 PHB fibers increase with the increase in extrusion temperature and draw-down ratio in the ranges studied. High birefringence, indicating the presence of mesophase is observed between 265 and 300°C on a hot stage polarizing microscope. X-ray diffraction patterns show that the molecular orientation increased with increasing draw-down ratio. Scanning electron microscopy of these fibers shows a well-developed highly oriented fibrillar structure. Superior mechanical performance of fibers spun at around 275°C are attributed to the presence of nematic mesophase in the polymer melt. © 1993 John Wiley & Sons, Inc.     

Effects of the processing conditions and blending with linear low-density polyethylene on the properties of low-density polyethylene films

Effects of blending low-density polyethylene (LDPE) with linear low-density polyethylene (LLDPE) were studied on extrusion blown films. The tensile strength, the tear strength, the elongation at break, as well as haze showed more or less additivity between the properties of LDPE and LLDPE except in the range of 20–40% where synergistic effects were observed. The LLDPE had higher tensile strength and elongation at break than did the LDPE in both test directions, as well as higher tear strength in the transverse direction. The impact energies of the LLDPE and the LDPE were approximately the same, but the tear strength of the LLDPE was lower than that of LDPE in the machine direction. The comparative mechanical properties strongly depend on the processing conditions and structural parameters such as the molecular weight and the molecular weight distribution of both classes of materials. The LLDPE in this study had a higher molecular weight in comparison to the LDPE of the study, as implied from its lower melt flow index (MFI) in comparison to that of the LDPE. The effects of processing conditions such as the blow-up ratio (BUR) and the draw-down ratio (DDR) were also studied at 20/80 (LLDPE/LDPE) ratio. Tensile strength, elongation at break, and tear strength in both directions became equalized, and the impact energy decreased as the BUR and the DDR approached each other.     

Melt strength of polypropylene: Its relevance to thermoforming

The melt strength of homopolymer, copolymer and high melt strength (HMS) grades of polypropylene (PP) was measured to assess the sagging resistance of PP for thermoforming applications. Acrylonitrile-butadiene-styrene (ABS), which can be easily processed during thermoforming, was also studied in this work. A polymer with high melt strength is considered to have a better sagging resistance. The melt strength measurements were carried out using a Gottfert “Rheotens” melt strength tester. The melt strength of the polymers increased with decreasing temperature and increasing extrusion rate. ABS generally had the highest melt strength in the low extrusion temperature region approaching the thermoforming region, indicating that it has a good sagging resistance during thermoforming. The HMS PP had significantly higher melt strength than conventional PP grades; therefore HMS PP is expected to have an improved sagging resistance. For conventional PP, melt strength was higher for the lower melt flow index (MFI) grades. A sharp increase in the melt strength was observed for conventional PP at low extrusion temperature, probably due to flow-induced crystallization of the PP. These results indicate that to minimise the sagging problem with conventional PP, low MFI grades should be used and thermoforming should be performed at temperatures close to the melting point of PP.     

Analysis of melt spinning master-curves of low density polyethylene

The extensional rheological properties of a low density polyethylene (LDPE) melt were studied by using melt spinning technique. Based on the extension properties of the LDPE melt under experimental conditions, the melt spinning master-curves were plotted by introducing scaling factor b and the draw ratio λ. The scaling factor b shows the combination effects on the preorientation before extension, the unwrapping and orientation of molecular chains during extension. Several linear relationships between b and temperature, log b and the logarithm of extrusion flow rate v₀ (log v₀) have been investigated. By using the values of b and the reference curve, the extension viscosity curves with different temperature and extrusion flow rate could be calculated, thus the measurement range of melt spinning technique would be extended effectively. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Rheological and mechanical properties in polyethylene blends

Melt rheology and mechanical properties in linear low density polyethylene (LLDPE)/low density polyethylene (LDPE), LLDPE/high density polyethylene (HDPE), and HDPE/LDPE blends were investigated. All three blends were miscible in the melt, but the LLDPE/LDPE and HDPE/LDPE blends exibiled two crystallization and melting temperatures, indicating that those blends phase separated upon cooling from the melt. The melt strength of the blends increased with increasing molecular weight of the LDPE that was used. The mechanical properties of the LLDPE/LDPE blend were higher than claculated from a simple rule of mixtures, whiele those of the LLDPE/HDPE blend conformed to the rule of mixtures, but the properties of HDPE/LDPE were less than the rule of mixtures prediction.     

Correlation of blown film optical properties with resin properties

The optical properties of conventional, free-radical polymerized low density polyethylene (LDPE) blown films are due essentially to surface irregularities that develop during fabrication. Past studies have shown that the extent to which these irregularities occur (and therefore optical properties) correlates well with the melt elasticity of the resin. Specifically, it has been shown that resins with higher melt elasticity result in films with poorer optical properties. However, it was recently reported that the optical properties of film blown from a Sci of three generically similar LDPE resins were found to correlate with the crystallization kinetics of the resins. Specifically, it was reported that the resins that exhibited faster crystallization rates produced films with better optical properties. This present work shows, however, that this apparent correlation is only coincidental. It has been shown that resins exhibiting faster crystallization rates do not necessarily result in films with better optical properties. On the other hand, it has been shown that resins with higher melt elasticity consistently result in films with poorer optical properties.     

Elongation properties of polyethylene melts

The extensional rheological properties of three grades of polyethylene melts, low density polyethylene (LDPE), linear low density polyethylene (LLDPE), and high density polyethylene (HDPE) were measured using a melt spinning technique under the test conditions with temperature ranging from 150 to 210°C and extrusion rate varying from 11.25 to 22.50 mm s^?1. The results showed that the melt strength decreased with a rise of temperature while increased with an increase of extensional rate. With the rise of extensional strain rate and temperature, the melt extensional viscosity decreased. The extensional stress and viscosity reduced with increasing extrusion velocity when the temperature and extensional rate were constant. Moreover, the melt strength and extensional viscosity of the LDPE resin was the highest and the LLDPE was the lowest under the same experimental conditions. POLYM. ENG. SCI., 2011. © 2011 Society of Plastics Engineers     

Crystalline-state extrusion of low density polyethylenes

Three low density polyethylenes, one long branched (A) and two linear (B and C), have been solid-state-extruded at several constant temperatures from ambient to 80°C and to draw ratios ? 8. The initial densities and melt indices of A, B, and C are 0.920, 0.920, and 0.935 g/cm³, and 1.9, 0.8, and 1.2, respectively. Melt-crystallized cylindrical billets were extruded through conical dies in an Instron Capillary Rheometer. The linear polymers were found to draw by extrusion more readily than the branched; all three strain-harden. Density, birefringence, tensile, and thermal properties have been evaluated as functions of extrusion temperature and draw ratio. Despite a measured loss via die swell, substantial orientation takes place during solid-state extrusion as evidenced by increases in transparency, birefringence, and tensile modulus (up to 4.5 times that of the original isotropic polymer). Depending on the polymer and the draw temperature, density does go through a minimum or shows a monotonic increase with draw by extrusion. A minimum in modulus is also observed at low draw and at all draw temperatures for all three polymers. The highest tensile moduli achieved are 0.73, 0.46, and 1.5 GPa for A, B, and C, respectively, at their highest draw ratio. The melting point for polymer B decreases with extrusion draw ratio, whereas it remains constant after a small initial drop, for the two others. For all three low density polyethylenes, birefringence increases rapidly with extrusion draw and then levels off at high draw. The birefringence limit is similar for A and B, i.e., 0.046 ± 0.004, but higher for C, i.e., 0.068 ± 0.009. This work extends beyond others in that it studies the effect of short as well as long branches in solid-state extrusion by comparing the linear and long branched LDPE polymers and LDPE with prior evaluations of HDPE.     

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     

Correlation between entry pressure losses and elongation viscosity of polyethylene melts

The correlation between the entry pressure drop and elongation viscosity during entry converging flow of polymer melts was discussed in this article. The entry pressure drop during extrusion of a low density polyethylene (LDPE) melt and a linear low density polyethylene (LLDPE) melt was measured by means of a capillary rheometer under test conditions with temperature of 170 °C and shear rate varying from 10 to 300 s⁻¹. The results showed that the entry pressure drop increased nonlinearly with an increase of the shear stain rate, and the variation of entry pressure drop of the two melts was close to each other. The melt elongation viscosity of the two resins was estimated using Cogswell equation from the measured entry pressure drop data, and the predictions were compared with the melt extension viscosity measured by using a melt spinning technique published in literature. It was found that the melt extension viscosity from entry converging flow was slightly lower than that from melt spinning technique under the same temperature and extension strain rate.     

Thermal,mechanical, and barrier properties of polyethylene/surlyn/organoclay nanocomposites blown films prepared by different mixing methods

(Low‐density polyethylene) (LDPE)/clay nanocomposites were prepared by melt blending in a twin‐screw extruder by using different mixing methods. Zinc‐neutralized carboxylate ionomer was used as a compatibilizer. Blown films of the nanocomposites were then prepared. The effect of mixing method on the clay dispersion and properties of the nanocomposites was evaluated by wide‐angle X‐ray diffraction analysis, mechanical properties, thermal properties, and barrier properties. The structure and properties of nanocomposites containing different amounts of nanoclay prepared by selected mixing techniques were also investigated. It was found that melt compounding of Surlyn/clay masterbatch with pure LDPE and Surlyn (two‐step‐a method) results in better dispersion and intercalation of the nanofillers than melt mixing of LDPE/Surlyn/clay masterbatch with pure LDPE and surlyn (two‐step‐b method) and direct mixing of LDPE with clay. The films containing ionomer have good barrier properties. A wide‐angle X‐ray diffraction pattern indicates that intercalation of polymer chains into the clay galleries decreases by increasing the clay content. Barrier properties and tensile modulus of the films were improved by increasing the clay content. In addition, tensile strength increased in the machine direction, but it decreased in the transverse direction by increasing the clay content. DSC results showed that increasing the clay content does not show significant change in the melting and crystallization temperatures. The results of thermogravimetric analysis showed that the thermal stability of the nanocomposites decreased by increasing the clay content more than 1 wt%. J. VINYL ADDIT. TECHNOL., 21:60–69, 2015. © 2014 Society of Plastics Engineers     

Physical extruder foaming of poly(lactic acid)—processing and foam properties

The article describes extrusion foaming of poly(lactic acid) (PLA) using carbon dioxide in the supercritical state as foaming agent emphasizing the steps required to establish a stable extrusion process. Low melt strength of PLA plays a role in optimizing processing conditions. The tests included PLA grades of different viscosity in addition to a chain extender. Processing at low temperature is possible due to the plasticizing effect of the CO₂ on the PLA melt and a sufficiently low melt temperature is also a prerequisite in production of stable foams due to improved melt strength. Foams were characterized by density, cell structure, crystallinity, and mechanical properties in compression. Low density, microcellular foams with density down to 20–30 kg/m³ were obtained for three different PLA grades. Varying die temperature and pressure drop rate we can explain observed abrupt drops in density with increasing CO₂ content by the interplay between cell nucleation and gas diffusivity at given temperatures. An effect on melt strength similar to using a chain extender is achieved by lowering the melt temperature at the die. Observed variations in sample crystallinity do not correlate with foam density. The PLA foams have good energy absorption capability. POLYM. ENG. SCI., 2013. © 2012 Society of Plastics Engineers