Kanai / Campbell Film Processing

1. Auflage 2013
ISBN: 978-3-446-40179-2
Verlag: Carl Hanser
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 458 Seiten

The manufacturing process for preparing very thin polymer products has developed into what is arguably the largest outlet for synthetic polymers. The central theme of this volume is the developments in process hardware and operating techniques that permit increasingly high production rates, optimum property development, unusual degrees of molecular orientation, and the coextrusion of multi-layer, multi-component film and sheet. The strong relationships and the interdependence of these developments on the achievements in polymer design, such as rheology and mechanical and optical properties, are also discussed.
Contents:
· Film Processing Overview and Introductory Rheology
· Flat Die Analysis
· Spiral Die Analysis
· Die Control System of Film Thickness Distribution
· Kinematics, Dynamics and Physical Properties of Blown Film
· Bubble Instability: Experimental Evaluation
· Optical Properties and Structural Characteristics of Tubular Film
· Theoretical Analysis of Film Deformation Behavior in Casting
· Analysis of Draw Resonance Instability in the Film Casting Process
· Multilayer Films
· Biaxially Oriented Films
· Influence of Processing Conditions on Structure and Physical Properties of Biaxially Stretched Engineering Thermoplastics
· Theoretical Analysis of Tentering Process
· Double Bubble Tubular Film Process System and Theoretical Analysis of Stress Development and Scale-up Rule

Gregory A. Campbell, Ph.D., is Chief Technical Officer at Castle Associates, Jonesport, ME. He was previously professor and departmental chair of chemical engineeering at Clarkson University, NY. He formerly directed a research group at GM Research and managed polymer fabrication at Mobil Chemical Research. He is a Fellow and former Extrusion Board Member of the Society of Plastics Engineers (SPE).

Autoren/Hrsg.

Kanai, Toshitaka

Campbell, Gregory A.

Fachgebiete

• Technische Wissenschaften Verfahrenstechnik | Chemieingenieurwesen | Biotechnologie Technologie der Kunststoffe und Polymere
• Technische Wissenschaften Maschinenbau | Werkstoffkunde Produktionstechnik Fertigungstechnik

Inhaltsverzeichnis

1;Contents;10
2;1 Film Processing: Overview and Introductory Rheology;22
2.1;1.1 Introduction;23
2.2;1.2 Cast Film;23
2.3;1.3 Blown Film;24
2.4;1.4 Tentering;24
2.5;1.5 Double Bubble Process;25
2.6;1.6 Volume Contents;27
2.7;1.7 Rheological Considerations;28
2.7.1;1.7.1 Shear Rheology;28
2.7.2;1.7.2 Elongational Rheology;29
2.7.3;1.7.3 Literature Review;30
3;2.1 Flat Die Analysis;35
3.1;2.1.1 Introduction;36
3.2;2.1.2 Simple Die Flow;36
3.3;2.1.3 Theoretical One-Dimensional Analysis of the Flat Die;39
3.4;2.1.4 Two-Dimensional Numerical Analysis of the Flat Die;51
3.5;2.1.5 The Multilayer Flat Die;57
4;2.2 Spiral Die Analysis;60
4.1;2.2.1 Introduction;61
4.2;2.2.2 Annular Flow Geometry;61
4.3;2.2.3 Basic Design Considerations;66
4.4;2.2.4 Mathematical Modeling;68
5;2.3 Die Control System of Film Thickness Distribution;79
5.1;2.3.1 Introduction;80
5.2;2.3.2 Cast Film.;80
5.3;2.3.3 Blown Film;85
5.4;2.3.4 Outlook;91
6;3.1 Dynamics, Heat Transfer, and StructureDevelopment in Tubular Film Extrusion of Polymer Melt;94
6.1;3.1.1 Introduction;95
6.2;3.1.2 Rheological Measurement;95
6.3;3.1.3 Local Kinematics;98
6.4;3.1.4 Temperature Profiles;100
6.5;3.1.5 Heat Transfer;101
6.6;3.1.6 Crystallization Rate;106
6.7;3.1.7 Theoretical Analysis;107
6.8;3.1.8 Dimensionless Analysis;114
6.9;3.1.9 Predictions of the Model;116
6.10;3.1.10 Physical Properties of High Molecular Weight HDPE Tubular Film;118
6.11;3.1.11 Scaleup of High Molecular Weight HDPE;121
6.12;3.1.12 Processability;130
7;3.2 Kinematics, Dynamics, and Physical Properties of Blown Film;134
7.1;3.2.1 Introduction;135
7.2;3.2.2 Single-Phase Model Dynamics;138
7.3;3.2.3 Fluid-Solid Models;143
7.4;3.2.4 Property Development in Blown Film;151
7.5;3.2.5 Summary;159
7.6;3.4 Optical Properties and Structural;177
7.6.1;3.4.1;178
7.6.2;Introduction;178
7.6.3;3.4.2 Background;178
7.6.3.1;3.4.2.1 Structural Characteristics;178
7.6.3.2;3.4.2.2 Electromagnetic Theory and Optical Characteristics;179
7.6.3.3;3.4.2.4 Orientation;183
7.6.3.4;3.4.2.5 Interaction of Electromagnetic Waves with Surfaces;185
7.6.4;3.4.3 Measurement Methods;187
7.6.4.1;3.4.3.2 Measurement of Orientation in Films;189
7.6.5;4.1.1;202
7.6.6;Introduction;202
7.6.7;4.1.2 Analysis of Film Deformation under Steady State;202
7.6.8;4.1.4 Analysis of Neck-In and Edge Bead Phenomena;218
7.6.9;Relevance of the Problem in the Film Industry;233
7.6.10;Draw Resonance in Newtonian Fluids;233
7.6.10.1;4.2.4.2 Viscoelastic Fluids;239
7.6.11;4.2.6 Conclusion;245
7.6.12;5.4 Coextrusion of Cast Film/Sheet;249
7.6.13;5.5 Coextrusion Feedblock and Multimanifold Dies;250
7.6.14;5.7 Coextrusion of Blown Film;257
7.6.15;5.8 Coextrusion Equipment Considerations and Auxiliaries;259
8;3.3 Bubble Instability: ExperimentalEvaluation;162
8.1;3.3.1 Introduction;163
8.2;3.3.2 Theory;165
8.3;3.3.3 Qualitative Experimental Analysis;165
8.4;3.3.4 Quantitative Stability Analysis;166
8.5;3.3.5 Summary;176
9;3.4 Optical Properties and Structural Characteristics of Tubular Film;177
9.1;3.4.1 Introduction;178
9.2;3.4.2 Background;178
9.3;3.4.3 Measurement Methods.;187
9.4;3.4.4 Orientation Development in Vitrifying Tubular Film;191
9.5;3.4.5 Structure Development in Crystalline Tubular Film;192
9.6;3.4.6 Mechanism of Haze;195
10;4.1 Theoretical Analysis of Film Deformation Behavior in Casting;201
10.1;4.1.1 Introduction;202
10.2;4.1.2 Analysis of Film Deformation under Steady State;202
10.3;4.1.3 Analysis of Film Temperature;212
10.4;4.1.4 Analysis of Neck-In and Edge Bead Phenomena;218
10.5;4.1.5 Influence of Processing Factors on Film Properties;226
10.6;4.1.6 Concluding Remarks;229
11;4.2 Analysis of Draw Resonance Instabilityin the Film Casting Process;231
11.1;4.2.1 Introducation;232
11.2;4.2.2 Relevance of the Problem in the Film Industry;233
11.3;4.2.3 Draw Resonance in Newtonian Fluids;233
11.4;4.2.4 Draw Resonance in Non-Newtonian Fluids;237
11.5;4.2.5 Mechanism of Draw Resonance;243
11.6;4.2.6 Conclusion;245
12;5 Multilayer Films;246
12.1;5.1 Introduction;247
12.2;5.2 Monolayer Cast Film Extrusion;247
12.3;5.3 Monolayer Blown Film Extrusion;247
12.4;5.4 Coextrusion of Cast Film/Sheet;249
12.5;5.5 Coextrusion Feedblock and Multimanifold Dies;250
12.6;5.6 Coextrusion of Flexible Cast Film;255
12.7;5.7 Coextrusion of Blown Film;257
12.8;5.8 Coextrusion Equipment Considerations and Auxiliaries;259
12.8.1;5.8.1 Extruder Screws for Coextrusion;259
12.8.2;5.8.2 Mixers for Coextrusion;260
12.8.3;5.8.3 Gear Pumps for Coextrusion;261
12.8.4;5.8.4 Gauge Control of Coextruded Sheet and Film;262
12.8.5;5.8.5 Coextrusion Process Control;262
12.9;5.9 Coextrusion Coating with Lamination;263
12.10;5.10 Concluding Thought;263
13;6.1 Biaxially Oriented Film;265
13.1;6.1.1 Introduction;266
13.2;6.1.2 Outline of the Tentering System Machine;266
13.3;6.1.3 Polymer Handling;270
13.4;6.1.4 The Extrusion Process;270
13.5;6.1.5 Filter and Die;277
13.6;6.1.6 The Casting Process;279
13.7;6.1.7 Stretching and Annealing Processes;286
13.8;6.1.8 Takeoff and Winding Processe;294
13.9;6.1.9 Process Control;295
13.10;6.1.10 Closing Comments;300
14;6.2 Influence of Processing Conditions on Structure and Physical Properties of Biaxially Stretched Engineering Thermoplastics;302
14.1;6.2.1 Chemistry of Polyesters and Its Importance in Processing;303
14.2;6.2.2 Solid State Phase Behavior of PET;303
14.3;6.2.3 PET Film Technology;305
14.4;6.2.4 Stress-Induced Crystallization;306
14.5;6.2.5 Development of Structure with Deformation;306
14.6;6.2.6 Dynamic and Static Mechanical Properties;324
14.7;6.2.7 Other Properties of Interest;334
14.8;Solid State Phase Behavior of PET;303
14.8.1;6.2.5.1 Stretching of PET below;307
14.8.2;6.2.5.2 Stretching of PET above;307
14.8.3;6.2.5.3 Deformation Behavior of PET in the Rubbery Region and Its Relationship to Thickness Uniformity;307
14.8.4;6.2.5.4 Structure and Morphology Developed by Biaxial Stretching of PET;309
14.8.5;3x3;313
14.8.6;3xl;313
14.8.7;6.2.5.6 Crystallinity and Thermal Properties;319
14.8.8;6.2.6.4 One-Step (Simultaneous) Biaxially Stretched Film;331
14.8.9;6.2.6.5 Two-Step Biaxially Stretched Films;331
15;6.3 Stretching Conditions, Orientation, and Physical Properties of Biaxially Oriented Film;341
15.1;6.3.1 Introduction;342
15.2;6.3.2 Outline of the Film Making Process;343
15.3;6.3.3 Sequential (LD . TD) Stretchin;345
15.4;6.3.4 General Properties of PET Film;349
15.5;6.3.5 Quality Improvement of PET Films;360
16;6.4 Theoretical Analysis ofthe Tentering Process;374
16.1;6.4.1 Introduction;375
16.2;6.4.2 Mathematical Model for the Extension of Thin Uneven Rubber Film;375
16.3;6.4.3 Numerical Analysis of Film Extension by the Finite Element Method (FEM);387
17;7.1 Double Bubble Tubular Film Process System and Theoretical Analysis of Stress Development and Scaleup Rule;407
17.1;7.1.1 Introduction;408
17.2;7.1.2 Technical Trends and Typical Applications;408
17.3;7.1.3 Experimental and Theoretical Background;409
17.4;7.1.4 Results and Discussion;412
17.5;7.1.5 On Adaptability to Noncrystalline Resin (PS);421
17.6;7.1.6 The Film Stretching Process and Its Physical Properties (Simultaneous versus Multistage);423
17.7;7.1.7 The Heat Set Technique (Production of Shrink Film);425
17.8;7.1.8 Development of Peripheral Technology for the Double Bubble Tubular BiaxialStretching Process;426
17.9;7.1.9 Prospective Directions of Double Bubble Tubular Biaxial Stretching;428
18;7.2 Biaxially Oriented Double BubbleTubularFilm: Process and Film Character;433
18.1;7.2.1 Introduction;434
18.2;7.2.2 Process Technologies and Structural Characteristics of Double Bubble Tubular Film;434
18.3;7.2.3 Final Comments.;448
19;Index;452

Über Autor(innen)

Campbell, Gregory A.
Gregory A. Campbell, Ph.D., is Chief Technical Officer at Castle Associates, Jonesport, ME. He was previously professor and departmental chair of chemical engineeering at Clarkson University, NY. He formerly directed a research group at GM Research and managed polymer fabrication at Mobil Chemical Research. He is a Fellow and former Extrusion Board Member of the Society of Plastics Engineers (SPE).