Handbook of Plastic Films

Plastic films are high-performance materials which play an essential part in modern life. Plastic films are mostly used in packaging applications but as will be seen from this book they are also used in the agricultural, medical and engineering fields. The plastics films industry uses state-of-the-art manufacturing processes and is continuously seeking out new technologies to improve its performance.

The understanding of the nature of plastic films, their production techniques, applications and their characterisation is essential for producing new types of plastic films. This handbook has been written to discuss the production and main uses of plastic films.

About the editor
Elsayed Abdel-Bary took his first degree at Cairo University and studied for his PhD at the Institute of Fine Chemical Technology in Moscow. He became a Professor in the Faculty of Science at Mansoura University in 1979 and subsequently founded the Universitys Polymer Research Centre. He has published widely on the subject of polymer science, to date he has over 100 papers/book chapters credited to him. Elsayed is the Editor-in-Chief of Packplast International and Interplas International, the Vice-President of the Egyptian Chemical Society and a member of the IUPAC Academy of Scientific Research and Technology.

1 Technology of Polyolefin Film Production
1.1 Introduction
1.2 Structures of the Polyolefins
1.2.1 Low-Density Polyethylene (LDPE
1.2.2 High-Density Polyethylene (HDPE,MDPE,UHMWPE
1.2.3 Linear Low-Density Polyethylene (LLDPE
1.2.4 Very-and Ultra-Low-Density Polyethylene (VLDPE,ULDPE
1.2.5 Polypropylene (PP
1.2.6 Polypropylene Copolymers
1.3 Morphology of Polyolefin Films
1.4 Rheological Characterisation of the Polyolefins
1.4.1 High-Density Polyethylene
1.4.2 Linear Low-Density Polyethylene
1.4.3 Very-and Ultra-Low-Density Polyethylene
1.4.4 Low-Density Polyethylene,Long Branches
1.4.5 Polypropylene
1.5 Blown Film Production (Tubular Extrusion
1.5.1 Extruder Characteristics
1.5.2 Screw Design
1.5.3 Frost-line and Blow Ratio
1.6 Cast Film Production
1.6.1 Extrusion Conditions
1.6.2 Calendering Finishing
1.6.3 Extrusion Coating
1.7 Orientation of the Film
1.7.1 Orientation During Blowing
1.7.2 Orientation by Drawing
1.7.3 Biaxial Orientation (Biaxially Oriented PP,BOPP)
1.8 Surface Properties
1.8.1 Gloss
1.8.2 Haze
1.8.3 Surface Energy
1.8.4 Slip
1.8.5 Blocking
1.9 Surface Modification
1.9.1 Corona Discharge
1.9.2 Antiblocking
1.9.3 Slip Additives
1.9.4 Lubricants
1.9.5 Antistatic Agents
1.10 Internal Additives
1.10.1 Antioxidants
1.10.2 Ultraviolet Absorbers
1.11 Mechanical Properties
1.11.1 Tensile Properties
1.11.2 Impact Properties
1.11.3 Dynamic Mechanical Properties
1.11.4 Dielectric Properties
1.12 Microscopic Examination
1.12.1 Optical - Polarised Light Effect with Strain
1.12.2 Scanning Electron Microscopy (SEM)- Etching
1.12.3 Atomic Force Microscopy (AFM)
1.13 Thermal Analysis
1.13.1 Differential Scanning Calorimetry (DSC)
1.13.2 Temperature-Modulated DSC (TMDSC)
1.14 Infrared Spectroscopy
1.14.1 Characterisation
1.14.2 Composition Analysis of Blends and Laminates
1.14.3 Surface Analysis
1.14.4 Other Properties
1.15 Applications
1.15.1 Packaging
1.15.2 Laminated Films
1.15.3 Coextruded Films
1.15.4 Heat Sealing
1.15.5 Agriculture
1.16 Conclusion

2 Processing of Polyethylene Films
2.1 Introduction
2.2 Parameters Influencing Resin Basic Properties
2.2.1 Molecular Weight (Molar Mass)and Dispersity Index
2.2.2 Melt Index (Flow Properties
2.2.3 Density
2.2.4 Chain Branching
2.2.5 Intrinsic Viscosity
2.2.6 Melting Point and Heat of Fusion
2.2.7 Melt Properties - Rheology
2.2.8 Elongational Viscosity
2.2.9 Elasticity
2.3 Blown Film Extrusion (Tubular Film
2.3.1 Introduction
2.3.2 Description of the Blown Film Process
2.3.3 Various Ways of Cooling the Film
2.3.4 Extruder Size
2.3.5 Horsepower
2.3.6 Selection of Extrusion Equipment
2.4 Cast Film Extrusion
2.4.1 Description of the Cast Film Process
2.4.2 Effects of Extrusion Variables on Film Characteristics
2.4.3 Effect of Blow-up Ratio on Film Properties
2.5 Processing Troubleshooting Guidelines
2.6 Shrink Film
2.6.1 Shrink Film Types
2.6.2 Shrink Film Properties
2.6.3 The Manufacture of Shrink Film
2.6.4 Shrink Tunnels and Ovens

3. Processing Conditions and Durability of Polypropylene Films
3.1 Introduction
3.2 Structures and Synthesis
3.3 Film Processing
3.4 Additives
3.5 Ultraviolet Degradation of Polypropylene
3.5.1 UV Degradation Mechanisms
3.5.2 Effect of UV Degradation on Molecular Structure and Properties of PP
3.5.3 Stabilisation of PP by Additives
3.6 Case Studies
3.6.1 Materials and Experimental Procedures
3.6.2 Durability-Microstructure Relationship
3.6.3 Durability-Processing Condition Relationship
3.6.4 Durability