TITLE: PROCESS FOR THE PRODUCTION OF CAST FILM FROM HIGH-DENSITY POLYETHYLENE
European Patent Application EP0278569 A3

ABSTRACT:
Abstract of EP0278569
Process for the production of cast film from a polymer composition
based on high-density polyethylene, the molten polymer composition
being fed through a rectangular die by means of an extruder and
subsequently being cooled and rolled up via one or more cooling rolls,
the polymer melt being processed at a melt temperature below 220 ◊& C,
measured at the die opening.

INVENTORS:
Van Der, Molen Theodorus Jacobus

APPLICATION NUMBER: EP19880200202
PUBLICATION DATE: 09/12/1990
FILING DATE: 02/05/1988

ASSIGNEE: STAMICARBON B.V.
INTERNATIONAL CLASSES: B29C47/00; B29C47/86; B29C55/18; (IPC1-7): B29C47/86; C08J5/18
EUROPEAN CLASSES: B29C47/00B; B29C47/86; B29C55/18

CLAIMS:
1. Process for the production of cast film from a polymer composition
based on high-density polyethylene, the molten polymer composition
being fed through a rectangular die by means of an extruder and
subsequently being cooled and rolled up via one or more cooling rolls,
characterized in that the polymer melt is processed at a melt
temperature below 220 ◊& C, measured at the die opening.
2. Process according to claim 1, characterized in that the polymer
composition is processed at a melt temperature below 200 ◊& C, measured
at the die opening.
3. Process according to claim 2, characterized in that the polymer
composition is processed at a melt temperature below 180 ◊& C, measured
at the die opening.
4. Process according to any of claims 1-3, characterized in that a
polymer composition with a melt index between 1 and 100 dg/min is used.
5. Process according to claim 4, characterized in that a polymer
composition with a melt index between 4 and 50 dg/min is used.
6. Process according to claim 5, characterized in that a polymer
composition with a melt index between 8 and 25 dg/min is used.
7. Process according to any one of claims 1-6, characterized in that a
die width of at least 0.2 mm is used.
8. Process according to claim 7, characterized in that a die width of
at least 1.5 mm and at most 10 mm is used.
9. Process according to any one of claims 1-8, characterized in that
irradiated polyethylene is used.
10. Process according to any one of claims 1-8, characterized in that
polyethylene treated with a compound producing free radicals is used.
11. Cast film, produced according to any one of claims 1-10, with a
thickness of 1-100 micronm and a width of 1-500 mm.

DESCRIPTION:
PROCESS FOR THE PRODUCTION OF CAST FILM FROM HIGH-DENSITY POLYETHYLENE
The invention relates to a process for the production of cast film from
a polymer composition based on high-density polyethylene, the molten
polymer composition being fed through a rectangular die by means of an
extruder and subsequently being cooled and rolled up via one or more
cooling rolls.
The polymer melt is usually processed at high temperatures. A
temperature of 280 ◊& C is not exceptional.
Cast film manufactured from high-density polyethylene is commonly used
as packaging material. The main requirements to be met by the packaging
material are high stiffness, good tensile strength and good
water-vapour-barrier properties.
The aim of the present invention is to provide a process for the
production of cast film from a polymer composition based on
high-density polyethylene, resulting in a film with improved mechanical
properties, in particular with improved stiffness, yield stress and
tensile strength. This aim is achieved by processing the molten polymer
composition at a melt temperature of less than 220 ◊& C, measured at
the die opening. Processing under the conditions according to the
invention surprisingly results in particular (monoaxial) orientation
effects which improve the mechanical properties of the film with
respect to the conventional processing techniques. The stiffness and
tensile strength in particular increase. This effect is greater at melt
temperatures below 200 ◊& C at the die opening, in particular at
temperatures below 180 ◊& C.
It is not recommended to apply temperatures lower than 140 ◊& C, in
view of the melting point of high-density polyethylene.
Polymer compositions suitable to be processed according to the
invention generally contain at least 50 wt% polyethylene with a density
of 940 kg/m<3> or higher. Small amounts of comonomers may be
incorporated in this polyethylene; however, this may not cause the
density to drop below 940 kg/dm<3>. Therefore the polyethylene
preferably contains at most 5 mole% of 1-alkene. If so desired, the
polyethylene may contain a small amount of polyunsaturated compounds,
as described in NL-A 85.02747.
The high-density polyethylene may be mixed with other polymers, for
example polyethylenes with densities below 940 kg/m<3>, or
polypropylene. However, preferably there is at least 70 wt% of
polyethylene, more in particular at least 85 wt%, based on the total
polymer.
A pretreatment of the high-density polyethylene, which is usually
available as granulate, may further improve the results. Irradiation of
the granulate before it is introduced into the extruder improves
stiffness, tensile strength and yield stress. This irradiation may be
effected in the usual manner, for example with an electron beam or
gamma-radiation. The intensity of the radiation may vary from 0.01 to 2
MRad, preferably from 0.05 to 1 MRad. The amount of time for which the
polymer is subjected to irradiation depends on the intensity of the
radiation. In the case of more intense radiation a shorter irradiation
time will suffice, and vice versa. In general, the irradiation time
varies from several msec to several sec, for example from 5 msec to 2
sec, in particular from 10 msec to 1 sec.
It is also possible to cause a small number of free radicals to react
with the polyethylene for some time. This can be done with advantage
with a peroxide and during the extrusion which in any case takes place
in the processing of the polymer to form cast film. This process is
described in, for example, US-A-4,603,173, the contents of which are
included in the present patent.
In addition, various additives like stabilizers, lubricants, fillers,
colourants, waxes, etc. may also be present. In processing an ethylene
copolymer with one or more C3-C18 1-alkenes, fluorine elastomers, for
example, may be added to prevent or minimize melt fracture.
The quantity by weight of additives will usually not exceed 20% of the
quantity by weight of polymer.
The melt index of these polymer compositions, determined according to
ASTM D 1238, may have the usual values, for example between 1 and 100
dg/min. In view of the low processing temperature, it is, however,
recommendable to choose a melt index of not less than 4 dg/min. The
favourable effect of low temperature processing on the mechanical
properties decreases at melt indices above 50 dg/min, and is most
apparent at a melt index of at most 25 dg/min.
The advantage of the invention is that polymer compositions with a
relatively high melt index can also be processed to form cast film with
good mechanical properties.
Another advantage is that monoaxially oriented films are obtained
without the need of additional equipment.
A further advantage is that a degree of stiffness is reached which is
unattainable with the conventional processing techniques of the same
polymer composition, the stiffness being related to the density.
Yet another advantage is that a considerable amount of energy is saved,
because extrusion is effected at low temperatures - an advantage that
is further increased by using polyethylene with a relatively high melt
index.
Cast film is obtained by feeding a polymer melt through a rectangular
die and subsequently cooling it and rolling it up via one or more
cooling rolls. Die widths of 0.2 to 1.0 mm are commonly used in the
processing of polyethylene to form cast film and such widths may also
be applied in the process according to the invention. It is also
possible to use greater die widths, for example of 1.5 or 5 mm, and to
vary the geometry of the die. It has now been found that the mechanical
properties of the film improve with die widths of at least 1.5 mm and
at most 10 mm, in particular at most 5 mm.
These greater die widths combined with the low processing temperature
result in even better mechanical properties, in particular in good
stiffness and tensile strength.
After the polymer composition has left the die opening it is fed to one
or more cooling rolls. The distance between the die opening and the
first cooling roll, the so-called air gap, is of some influence on the
properties of the flat film produced. The same applies to the
temperature of the first cooling roll. An optimum setting of this
equipment is part of the common knowledge of anyone skilled in the art.
A so-called air knife is also commonly used in the manufacturing
process of cast film. It serves to improve the heat transfer from the
film to the cooling roll and to prevent air bubble inclusions.
The air knife can also be used in a process according to the invention.
It has been found that the position of the air knife with respect to
the film to be cooled (for example the distance), as well as its
setting (for instance the speed and temperature of the air) may affect
the results of the process according to the invention. An air
temperature of 25 ◊& C or less is preferable. Putting the air knife in
its optimum position and setting is easy for anyone skilled in the art.
A large range of different types of films can be manufactured with the
process according to the invention. Multi-layer film as well as
single-layer film can, for instance, be produced. It is also possible
to manufacture thin (for example 1 - 100 micron) and thick film (for
example 100 micron - 250 micron) as well as narrow (several
millimetres) and wide (several metres) films. This also includes the
so-called 'tapes'. The above process can be carried out with the usual
machines with their usual possibilities, set in the manner indicated in
the present invention.
The invention will now be elucidated with some examples. Cast film was
produced under the conditions indicated in the tables. The extruder
used was a Schwabenthan with a screw diameter of 30 mm. The length of
the rectangular die was 15 cm, the air gap 20 mm and the temperature of
the cooling roll 15 ◊& C. The temperature of the melt at the die
opening was determined through infrared measurement or with a
thermocouple. Of the film the following were determined: the modulus of
elasticity according to ASTM D 882 (ISO R 1184); yield stress and
tensile strength according to ISO R 527; Table 1 shows the results
obtained with polyethylene with a density of 962 kg/m3 (ASTM D 1505)
and a melt index (ASTM D 1238 cond. E) of 11 dg/min.
The results shown in Table 2 were obtained with the same polyethylene,
however, after irradiation with 0.2 MRad electron beam for about 1
second. M.D. = machine direction T.D. = direction perpendicular to M.D.
in the plane of the film. EMI5.1 EMI6.1