Professional Documents
Culture Documents
Processability
Processability
Coextrudability
Coextrudability
Physical Properties
Physical Properties
Barrier Properties
Barrier Properties
Economics
Economics
What Does A Specialty Resin
Have To Exhibit?
Good Processability:
Good Processability:
---
---
for the converter
for the converter
good drawability
good drawability
good
good
green
green
adhesion to substrates
adhesion to substrates
etc
etc
..
..
What Does A Specialty Resin
Have To Exhibit?
Good end
Good end
-
-
use properties:
use properties:
---
---
for the Packager
for the Packager
sealability
sealability
(through contaminants);
(through contaminants);
peelability
peelability
sometimes
sometimes
long term
long term
adhesion
adhesion
to adjacent layers and substrates
to adjacent layers and substrates
durability
durability
of seals / adhesions / barrier, when exposed to;
of seals / adhesions / barrier, when exposed to;
aggressive
aggressive
chemicals
chemicals
vacuum packaging
vacuum packaging
etc
etc
...
...
Selecting a Specialty Resin:
The Choices
POLYETHYLENE FAMILY
POLYETHYLENE FAMILY
LDPE
LDPE
LLDPE
LLDPE
HDPE
HDPE
mPE
mPE
POLYPROPYLENE
POLYPROPYLENE
CoPP extr/ctg
CoPP extr/ctg
CPP film
CPP film
SPECIALTY RESINS
SPECIALTY RESINS
E / VA
E / VA
E /
E /
acrylates
acrylates
E /
E /
terpolymers
terpolymers
Acid Copolymer
Acid Copolymer
Ionomer
Ionomer
PET
PET
Nylon, EVOH,
Nylon, EVOH,
...
...
EVA (ethylene vinyl acetate)
CHEMISTRY
Adding VA to the polymer gives:
Adding VA to the polymer gives:
1)
1)
lower crystallinity
lower crystallinity
2)
2)
slight polarity
slight polarity
CH CH
3 3
VA VA
l l
C = O C = O
l l
O O
l l
CH CH
2 2
CH CH
2 2
CH CH CH CH
2 2
CH CH
2 2
CH CH
2 2
EVA
Characteristics
Increasing the percent Vinyl Acetate:
Increasing the percent Vinyl Acetate:
increases toughness
increases toughness
increases flexibility
increases flexibility
increases optics
increases optics
increases tackiness
increases tackiness
increases
increases
vinegar
vinegar
odor
odor
increases
increases
EVA
Characteristics
EXTRUSION ISSUES:
EXTRUSION ISSUES:
Vinegar
Vinegar
you must
you must
purge it out well
purge it out well
before raising extruder
before raising extruder
temps back above 235C or before a shutdown.
temps back above 235C or before a shutdown.
EVA Resins
Selection Factors
2.0%
2.0%
-
-
50% VA / 0.35
50% VA / 0.35
-
-
43.0 MI (dg/min)
43.0 MI (dg/min)
DuPont, ExxonMobil, AT
DuPont, ExxonMobil, AT
-
-
Plastics, Equistar,
Plastics, Equistar,
Arkema
Arkema
, etc
, etc
...
...
A resin will be
A resin will be
chosen
chosen
FIRST
FIRST
based upon the end use
based upon the end use
performance
performance
characteristics needed, and the processability for
characteristics needed, and the processability for
extrusion coating, blown film, or cast film production.
extrusion coating, blown film, or cast film production.
EVA application examples
in Extrusion Coating
OPP
OPP
-
-
ink / primer / 18% EVA with slip
ink / primer / 18% EVA with slip
OPP
OPP
-
-
ink / adhesive // met
ink / adhesive // met
-
-
OPET / primer / PE / EVA
OPET / primer / PE / EVA
OPET
OPET
-
-
ink / adhesive // foil / PE / EVA
ink / adhesive // foil / PE / EVA
Cello
Cello
-
-
ink / primer / PE / foil / PE / EVA
ink / primer / PE / foil / PE / EVA
EVA application examples
in Film Extrusions
(HDPE
(HDPE
-
-
HDPE
HDPE
-
-
18% EVA with additives)
18% EVA with additives)
(
(
ionomer
ionomer
-
-
high% EVA)
high% EVA)
Ethylene Acrylate Copolymers
Features:
Features:
Used more in
Used more in
Industrial
Industrial
versus
versus
Packaging
Packaging
.
.
have
have
acrylate
acrylate
smell (instead of
smell (instead of
vinegar
vinegar
smell of EVA)
smell of EVA)
Suppliers:
Suppliers:
DuPont
DuPont
EBA, EEA, EMA;
EBA, EEA, EMA;
Mitsui
Mitsui
-
-
DuPont
DuPont
EEA;
EEA;
ExxonMobil
ExxonMobil
EnBA
EnBA
, EMA;
, EMA;
Arkema
Arkema
EBA, EMA;
EBA, EMA;
Dow
Dow
EEA;
EEA;
Westlake
Westlake
EBA, EMA
EBA, EMA
Mitsubishi
Mitsubishi
EMA, EEA
EMA, EEA
MA=methyl MA=methyl acrylate acrylate, EA=ethyl acrylate, BA=butyl acrylate, nBA=normal , EA=ethyl acrylate, BA=butyl acrylate, nBA=normal
butyl butyl acrylate acrylate, , iBA iBA=isobutyl =isobutyl acrylate acrylate
C --O - CH2 CH2 CH2 CH3
C -- O - CH2 CH3
C -- O - CH3
O -- C - CH3
O
O
O
EMA (ethylene-methyl acrylate)
O
Molecular structures
EBA (ethylene-butyl acrylate)
EEA (ethylene-ethyl acrylate)
EVA (ethylene- vinyl acetate)
Ethylene based Terpolymers
functionalized
functionalized
resins.
resins.
various
various
acrylate
acrylate
types,
types,
maleic
maleic
acid/anhydride, acrylic or
acid/anhydride, acrylic or
methacrylic
methacrylic
acids, carbon monoxide, vinyl acetate, etc
acids, carbon monoxide, vinyl acetate, etc
Suppliers:
Suppliers:
Arkema
Arkema
, ExxonMobil, Sumitomo
, ExxonMobil, Sumitomo
ACID COPOLYMER
CHEMISTRY
CH CH
3 3
| |
CH CH
2 2
CH CH
2 2
CH CH
2 2
C C CH CH
2 2
CH CH
2 2
CH CH
2 2
| |
C C
O OH O OH
HO O HO O
C C
| |
CH CH
2 2
CH CH
2 2
CH CH
2 2
C C CH CH
2 2
CH CH
2 2
CH CH
2 2
|
CH CH
3 3
MAA MAA
Adding MAA (or AA) to the polymer gives:
Adding MAA (or AA) to the polymer gives:
lower crystallinity
lower crystallinity
strong polarity
strong polarity
attraction between the polymer chains
attraction between the polymer chains
Types of Acid
Methacrylic acid:
Methacrylic acid:
(E/MAA)
(E/MAA)
Acrylic acid:
Acrylic acid:
(E/AA)
(E/AA)
C C C C C C
H H
O O
H H
C C H H H H
H H
OH OH
C C C C C C
H H
O O
H H
H H
OH OH
ACID COPOLYMER
CHARACTERISTICS
Excellent metal (aluminum) adhesion
Excellent metal (aluminum) adhesion
Low sealing temperature
Low sealing temperature
Very good hot tack strength (melt strength)
Very good hot tack strength (melt strength)
Broad sealing temperature range
Broad sealing temperature range
Good Toughness
Good Toughness
Good paper adhesion
Good paper adhesion
ACID COPOLYMER
Extrusion Issues:
Extrusion Issues:
needs to be
needs to be
purged
purged
can cross
can cross
-
-
link at high extruder temperature or
link at high extruder temperature or
residence time.
residence time.
ACID COPOLYMER RESINS
E/MAA (ethylene methacrylic acid):
E/MAA (ethylene methacrylic acid):
DuPont
DuPont
E/AA (ethylene acrylic acid):
E/AA (ethylene acrylic acid):
Dow, DuPont
Dow, DuPont
,
,
and ExxonMobil
and ExxonMobil
3%
3%
-
-
12% acid content common available commercially, but
12% acid content common available commercially, but
higher weight percent grades are also available.
higher weight percent grades are also available.
For extrusion: 0.8
For extrusion: 0.8
-
-
20 MI (dg/min)
20 MI (dg/min)
Additive grades available containing slip, antiblock, and / or
Additive grades available containing slip, antiblock, and / or
chill
chill
-
-
roll release.
roll release.
ACID COPOLYMER end-use
Extrusion Coating examples
Flavored edible oil sachet sealant Flavored edible oil sachet sealant
OPET or BONy OPET or BONy - - ink / primer / ACR ink / primer / ACR
Shampoo sachet foil adhesion/sealant Shampoo sachet foil adhesion/sealant
OPET OPET- -ink / primer / PE / foil / ACR ink / primer / PE / foil / ACR
Condiment foil adhesion/sealant Condiment foil adhesion/sealant
OPET OPET- -ink / primer / PE / foil / ACR ink / primer / PE / foil / ACR
OPET OPET- -ink / primer / white ACR / foil / LLDPE ink / primer / white ACR / foil / LLDPE
Toothpaste tube tie layer Toothpaste tube tie layer
PE film / (white PE PE film / (white PE- - ACR) / foil / (ACR ACR) / foil / (ACR PE )/ PE film PE )/ PE film
ACID COPOLYMER end-use
Film Extrusion examples
Edible oil standup pouch sealant Edible oil standup pouch sealant
OPET or BONy / ink / adhesive // (PE OPET or BONy / ink / adhesive // (PE - - ACR) ACR)
Shampoo sachet sealant Shampoo sachet sealant
OPET OPET- -ink / adhesive // ink / adhesive // vmPET vmPET / adhesive // (PE / adhesive // (PE - - ACR) ACR)
Cable Shielding thermal laminating film Cable Shielding thermal laminating film
Black PE / (PE Black PE / (PE - - ACR) //TL// 200u alu foil //TL// (ACR ACR) //TL// 200u alu foil //TL// (ACR - - PE) // cable PE) // cable
bundle bundle
IONOMER CHEMISTRY
CH CH
3 3
CH CH
3 3
CH CH
2 2
CH CH
2 2
CH CH
2 2
C C CH CH
2 2
CH CH
2 2
CH CH
2 2
C C
C C C C
O O O O
- -
O OH O OH
ION ION
O O
- -
O O
CH CH
3 3
C C
CH CH
2 2
C C CH CH
2 2
C C CH CH
2 2
CH CH
2 2
CH CH
2 2
CH CH
2 2
C C C C
O OH O OH
Partially neutralizing the acid:
Partially neutralizing the acid:
Thermally reversible
Thermally reversible
crosslinks
crosslinks
IONOMER
CHARACTERISTICS
Excellent hot tack strength
Excellent hot tack strength
Excellent optics
Excellent optics
Excellent oil/grease resistance
Excellent oil/grease resistance
Excellent formability
Excellent formability
Excellent seal through contamination
Excellent seal through contamination
Very good metal (aluminum) adhesion
Very good metal (aluminum) adhesion
Low sealing temperature
Low sealing temperature
Very broad sealing temperature range
Very broad sealing temperature range
Film Stiffness
Film Stiffness
0
10
20
30
40
50
60
70
80
90
100
0 2.
5
5 7.
5
1012
.5
1517
.5
2022
.5
25
Weight Percent
Comonomer
1
%
S
e
c
a
n
t
M
o
d
u
l
u
s
(
k
p
s
i
)
SSC mPE's
CGCT mPE's
Z-N LPE's
EVA resi ns
Ionomers
E/MAA
eva eva
ionomer ionomer
cgct cgct- -mpe mpe
ssc ssc- -mpe mpe
zn zn- -mpe mpe
emaa emaa
Stiffness
increases
w/neutralization
IONOMER
Extrusion Issues:
Extrusion Issues:
moisture sensitive
moisture sensitive
needs to be
needs to be
purged
purged
can cross
can cross
-
-
link at high extruder temperature or
link at high extruder temperature or
residence time
residence time
tackifiers
tackifiers
---
---
modified phenols for example
modified phenols for example
rubberizers
rubberizers
---
---
EPR or
EPR or
mVLDPE
mVLDPE
for example
for example
controlled contaminants
controlled contaminants
---
---
PB for example
PB for example
Suppliers:
Suppliers:
-
-
resin manufacturers;
resin manufacturers;
-
-
converter
converter
s own formulae
s own formulae
ready to use
ready to use
DuPont
DuPont
,
,
Toyo
Toyo
Petrolite
Petrolite
, Showa
, Showa
-
-
Denko,
Denko,
Hirodyne
Hirodyne
, etc
, etc
...
...
Selecting a resin for
Ext/Ctg as a Sealant:
Some Sealing Properties Some Processing Properties
Resin
Type
Hot
Tack
Peak
Str
Hot
Tack
Temp
Range
Low
Seal
Temp
Seal
Thru
Contam
Foil
Adh
Draw-
ability
Low Ext
Torque
Low
Neck-in
LDPE x x xx x X XX XXXX XX
mLLDPE xx x x xx X X X X
EVA xx xx xxxx xx NIL XX XX XX
EMA xx xx xxxx xx X XX XXX XX
mVLDPE xxxx x xxxx xxx X X X X
Acid
Copolymer
xxx xxx xxxx xxx XXXX XXX XXX XXX
Ionomer xxxx xxxx xxxx xxxx XXX XXXX XXX XXXX
x=fair performance xxxx=high performance
x=fair performance xxxx=high performance
Selecting a resin for
Film as a Sealant:
Some Sealing Properties Some Processing Properties
Resin
Type
Hot
Tack
Peak
Str
Hot
Tack
Temp
Range
Low
Seal
Temp
Seal
Thru
Contam
Tackiness Draw Low
Ext
Torque
Bubble
Strength
LDPE x x xx x X X XXXX XX
mLLDPE xx x x xx X XXX X X TO XX
EVA xx xx xxxx xx X TO XXXX XX XXX X TO XX
EMA xx xx xxxx xx X TO XXX XX XXX X
mVLDPE xxxx x xxxx xxx X TO XXX XXXX X X TO XX
Acid
Copolymer
xxx xxx xxxx xxx XX XXX XXX XXX
Ionomer xxxx xxxx xxxx xxxx XX XXXX XXX XXXX
x=fair performance xxxx=high performance
x=fair performance xxxx=high performance
POLYPROPYLENE
Made from propylene:
Made from propylene:
C C C C C C
H H
H H
H H H H
H H H H
H H
Polypropylene:
Polypropylene:
C C C C C C C C C C C C C C C C
H H
H H
H H
H H H H
H H
H H
H H H H
H H
H H
H H H H
H H
C C
H H
H H
C C
H H
H H
C C
H H
H H
C C
H H
H H
H H
H H
Film is often oriented (
Film is often oriented (
OPP
OPP
) to improve strength,
) to improve strength,
optics, and barrier properties
optics, and barrier properties
PROPERTIES OF
POLYPROPYLENE
Good clarity
Good clarity
Relatively low cost
Relatively low cost
Good moisture barrier
Good moisture barrier
Good seal strength
Good seal strength
No oxidation needed
No oxidation needed
POLYPROPYLENE
AS A SEALANT
Copolymer
Copolymer
-
-
propylene / ethylene
propylene / ethylene
Terpolymer
Terpolymer
-
-
propylene / ethylene /
propylene / ethylene /
butene
butene
or others...
or others...
reduced
reduced
crystallinity
crystallinity
OPP
OPP
-
-
ink /primer/LDPE/metal
ink /primer/LDPE/metal
-
-
OPP/CoPP
OPP/CoPP
extr.ctg
extr.ctg
.
.
OPP
OPP
-
-
ink/CoPP
ink/CoPP
extr.ctg
extr.ctg
.
.
OPP
OPP
-
-
ink/adhesive//
ink/adhesive//
vmCPP
vmCPP
cast film
cast film
Coextrudable Adhesive Resins
(TieResins)
coextrusion
coextrusion
e.g.
e.g.
--
--
EVA bonds to many things if the VA level is high
EVA bonds to many things if the VA level is high
enough, but perhaps not sufficiently.
enough, but perhaps not sufficiently.
Thus,
Thus,
tie
tie
tie
tie
Consult your
Consult your
tie
tie
resin supplier.
resin supplier.
Coextrudable Adhesive Resins
(TieResins)
Base Resins:
Base Resins:
EVA, PP
EVA, PP
Acrylate copolymers
Acrylate copolymers
Acid copolymers
Acid copolymers
Modifiers:
Modifiers:
maleic
maleic
anhydride
anhydride
olefinic
olefinic
tougheners
tougheners
tackifiers
tackifiers
rubbers
rubbers
Suppliers:
Suppliers:
DuPont
DuPont
Mitsui
Mitsui
Equistar
Equistar
Mitsubishi
Mitsubishi
Arkema
Arkema
Dow (Rohm & Haas)
Dow (Rohm & Haas)
DSM
DSM
Extrusion Issues:
Extrusion Issues:
must match
must match
rheology
rheology
layer uniformity, no
layer uniformity, no
interfacial instability
interfacial instability
extrusion
extrusion
process time
process time
is also an
is also an
importanat
importanat
factor.
factor.
Time of
Time of
cooling / drawing
cooling / drawing
of resins varies.
of resins varies.
Nylon
Types:
Types:
Nylon copolymers:
Nylon copolymers:
MP= 210C (410C)
MP= 210C (410C)
Nylon 6:
Nylon 6:
MP= 220C (430F)
MP= 220C (430F)
Nylon 66:
Nylon 66:
MP= 250C (480F)
MP= 250C (480F)
Amorphous Nylon
Amorphous Nylon
Suppliers:
Suppliers:
Nylon
Features:
Features:
Good
Good
thermoformability
thermoformability
Good optics
Good optics
Extrusion Issues:
Extrusion Issues:
moisture sensitive
moisture sensitive
high
high
moisture sensitive
moisture sensitive
thermal sensitivity
thermal sensitivity
high stiffness
high stiffness
Suppliers:
Suppliers:
Evalca
Evalca
, Kuraray, Nippon
, Kuraray, Nippon
-
-
Gohsei
Gohsei
Whats on the
Horizon?