Internally Deckled Coating Dies Resin Characteristics and - - PowerPoint PPT Presentation

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Internally Deckled Coating Dies Resin Characteristics and - - PowerPoint PPT Presentation

Feb 06, 2023 498 likes •800 views

Internally Deckled Coating Dies Resin Characteristics and Interaction with Die Design Session 4.1 Paper 7724 Gary Oliver Cloeren Incorporated Orange, TX USA Polymers Evaluated Sample- MFI G' (G prime) ZSV (Zero Shear viscosity) number

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SLIDE 1

Internally Deckled Coating Dies

Resin Characteristics and Interaction with Die Design

Session 4.1 Paper 7724

Gary Oliver Cloeren Incorporated Orange, TX USA

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SLIDE 2

Polymers Evaluated

Sample- number MFI Density Polymer Type MFI (g/10min) G' (G prime) Pa ZSV (Zero Shear viscosity) Pa*s 1 5.2 .940 Ionomer 5.1 100.7 6938 2 14 .950 Ionomer 17.1 133.3 2035 3 10 .930 Acid Co-Polymer 10.7 91.9 2861 4 5.1 .923 LDPE 4.9 96.7 6595 5 7 .917 LDPE 6.9 118.2 5127 6 8 .918 LDPE 7.8 116.9 4608 8 16 .923 LDPE 4.5 102.6 7914 9 16 .917 LDPE 15.3 96.4 1720 10 37 MFR .906 HOPP nr nr nr 11 8.5 .943 HDPE nr nr nr

nr = no usable results from resin testing

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SLIDE 3

Deckle Adjustment for Edge Bead Reduction

Plug Setting Relative to Blade & Rod Setting

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SLIDE 4

LIP LAND LENGTHS EVALUATED

Removable Lip Extrusion Coating Die Various Lip Lands

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SLIDE 5

2½ Plug Setting - 1¼ Blade Setting

Deckle Adjustment for Edge Bead Reduction

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SLIDE 6

Deckle Adjustment for Edge Bead Reduction

2 Plug Setting - 1 Blade Setting “Texas 2 Step”

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SLIDE 7

Polymer: Sample 6 Die Temp: 307 °C Melt Temp: 310 °C Line Speed: 122 M/min Target Coating Weight or Thickness: 38µ Air Gap: 150mm

Plug Blade 3.2mm 6.4mm 9.5mm 12.7mm 15.9mm 19mm 22.2mm 25.4mm 28.6mm 31.8mm 34.9mm 86.36 66.04 55.88 48.26 43.18 40.64 38.10 86.36 ½ 88.90 68.58 55.88 48.26 45.72 43.18 40.64 88.90 1 78.74 60.96 53.34 45.72 43.18 40.64 38.10 78.74 1½ ½ 71.12 58.42 48.26 43.18 40.64 38.10 35.56 71.12 1¾ ¾ 60.96 53.34 48.26 45.72 43.18 40.64 38.10 60.96 2 1¼ 30.48 35.56 38.10 35.56 35.56 35.56 38.10 30.48 2½ 1¼ 30.48 33.02 38.10 38.10 38.10 38.10 38.10 30.48 2½ 1½ 20.32 20.32 25.40 33.02 38.10 38.10 38.10 20.32 3 ¾ 3 1 3 1¼ 3½ 1 3½ 1¼ 3½ 1½

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SLIDE 8

Edge Bead Reduction Trial Results

Sample 1 MI=5.2 G’=100.7

0-0 ½-½ 1-½ 1-1 1 ½-1 2-1 2 ¼-1 ¼ 2 ¼-1 ½ 2 ½-1 ½

Deckle Settings Plug-Blade

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SLIDE 9

Edge Bead Reduction Trial Results

Sample 2 MI=17 G’=133.3

0-0 0-½ 0-1 ½-½ 1-½ 1-1 ½-1 2-1 2 ¼-1 ¼ 2 ¼-1 ½ 2 ½-1 ½ 2 ¾-1 ¾ 3-2 2-½ 3-½

Deckle Settings Plug-Blade

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SLIDE 10

Edge Bead Reduction Trial Results

Sample 3 MI=10 G’=91.9

0-0 ½-½ 1-½ 1-1 1 ½-1 2-1 2 ¼-1 ¼ 2 ½-1 ½

Deckle Settings Plug-Blade

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SLIDE 11

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Edge Bead Reduction Trial Results

Sample 4 MI=5.1 G’=96.7

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SLIDE 12

Edge Bead Reduction Trial Results

Sample 5 MI=7 G’=118.2

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SLIDE 13

Edge Bead Reduction Trial Results

Sample 6 MI= 8 G’=116.9

Deckle Settings Plug-Blade

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SLIDE 14

Deckle Settings Plug-Blade

Edge Bead Reduction Trial Results

Sample 8 MI=5.2 G’=102.6

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SLIDE 15

Edge Bead Reduction Trial Results

Sample 9 MI=16 G’=96.4

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SLIDE 16

Lip Land Trials

  • Coat Weight

25 gms/m2

  • Line Speed variable

90 – 305 m/minute

  • Lip Gap Constant

0.6mm

  • Lip Land variable

0 – 25.4mm

  • Five different polymers
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SLIDE 17

LIP LAND LENGTHS EVALUATED

25.4 mm

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SLIDE 18

LIP LAND LENGTHS EVALUATED

12.7 mm

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SLIDE 19

LIP LAND LENGTHS EVALUATED

6.35 mm

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SLIDE 20

LIP LAND LENGTHS EVALUATED

0 mm

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SLIDE 21

Extrusion Coating Polymers Evaluated

  • Sample 4 5.0 MFI .923 density LDPE

G’ 96.7

  • Sample 5 7.0 MFI .917 density LDPE

G’ 118.2

  • Sample 9 16 MFI .917 density LDPE

G’ 96.4

  • Sample 1035 MFR .906 density HOPP

nr

  • Sample 118.5 MFI .943 density HDPE

nr

nr – no reliable reading

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SLIDE 22

Lip Land Evaluation

Sample 4 5.1 MFI G’=96.7

35 40 45 50 55 60 91.4 152.4 213.4 274.3 304.8

Neckin mm Line Speed m/min

Neckin Sample 4

Land Length 0 mm Land Length 6.35 mm Land Length 12.7 mm Land Length 25.4 mm

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SLIDE 23

Lip Land Evaluation

Sample 5 – LDPE 7MFI G’=118.2

35 40 45 50 55 60 91.4 152.4 213.4 274.3 304.8

Neckin in mm Line Speed m/min

Neckin Sample 5

Land Length 0 mm Land Length 6.35 mm Land Length 12.7 mm Land Length 25.4 mm

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SLIDE 24

Lip Land Evaluation

Sample 9 - LDPE 16 MFI G’=96.4

35 40 45 50 55 60 91.4 152.4 213.4 274.3 304.8

Neckin in mm Line Speed m/min

Neckin Sample 9

Land Length 0 mm Land Length 6.35 mm Land Length 12.7 mm Land Length 25.4 mm

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SLIDE 25

Lip Land Evaluation

Sample 10 37 MFR .906 HOPP

72 82 92 102 112 122 132 142 152 162 91.4 152.4 213.4 274.3 304.8

Neckin in mm Line Speed m/min

Neckin Sample 10

Land Length 0 mm Land Length 6.35 mm Land Length 12.7 mm Land Length 25.4 mm

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SLIDE 26

Lip Land Evaluation

Sample 11 8.5 MFI .943 HDPE

72 82 92 102 112 122 132 142 152 162 91.4 152.4 213.4 274.3 304.8

Neckin in mm Line Speed m/min

Neckin Sample 11

Land Length 0 mm Land Length 6.35 mm Land Length 12.7 mm Land Length 25.4 mm

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SLIDE 27

Resin Charactistics vs. Edge Bead

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Resin Characteristics and Die Design - Oliver

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SLIDE 28

Summary

  • Samples examined with various viscoelastic properties
  • Edge Bead Reduction compared to viscoelastic

properties

  • Die land length examined compared to viscoelastic

properties

  • Few correlations
  • Work continues
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SLIDE 29

Special Thanks

  • Otto Plassmann -

INEOS Köln GmbH

  • Jim Cooper
  • Dow Plastics
  • Kelly Frey
  • CP Chemicals
  • Gary Jerdee
  • CP Chemicals
  • Erkki Laiho
  • Borealis Group
  • Scott Marks
  • DuPont

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Resin Characteristics and Die Design - Oliver