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    Gel Troubleshooting

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    Sid sid
    The document summarizes common causes of gels in plastic film production, including contamination, incomplete melting and mixing, thermal degradation, oxidation, and equipment issues. It discusses how gels can form from fiber contamination, cross-contamination between resins, poorly dispersed masterbatch concentrates, polymer blends with different melting properties, screw design problems, excessive temperature, shear or residence time in the extruder, oxidation during processing, and residual gels hanging up in the film die. Methods for identifying and addressing specific gel causes are also reviewed.

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    Gel Troubleshooting

    Uploaded by

    Sid sid
    75 views57 pages
    The document summarizes common causes of gels in plastic film production, including contamination, incomplete melting and mixing, thermal degradation, oxidation, and equipment issues. It discusses how gels can form from fiber contamination, cross-contamination between resins, poorly dispersed masterbatch concentrates, polymer blends with different melting properties, screw design problems, excessive temperature, shear or residence time in the extruder, oxidation during processing, and residual gels hanging up in the film die. Methods for identifying and addressing specific gel causes are also reviewed.

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    The document summarizes common causes of gels in plastic film production, including contamination, incomplete melting and mixing, thermal degradation, oxidation, and equipment issues. It discusses how gels can form from fiber contamination, cross-contamination between resins, poorly dispersed masterbatch concentrates, polymer blends with different melting properties, screw design problems, excessive temperature, shear or residence time in the extruder, oxidation during processing, and residual gels hanging up in the film die. Methods for identifying and addressing specific gel causes are also reviewed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    75 views57 pages

    Gel Troubleshooting

    Uploaded by

    Sid sid
    The document summarizes common causes of gels in plastic film production, including contamination, incomplete melting and mixing, thermal degradation, oxidation, and equipment issues. It discusses how gels can form from fiber contamination, cross-contamination between resins, poorly dispersed masterbatch concentrates, polymer blends with different melting properties, screw design problems, excessive temperature, shear or residence time in the extruder, oxidation during processing, and residual gels hanging up in the film die. Methods for identifying and addressing specific gel causes are also reviewed.

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    2007 PLACE

    Conference
    September 16-20
    St Louis, MO

    Gel Troubleshooting

    Presented by:
    Lou Piffer
    Senior Sales Engineer
    Davis-Standard, LLC
    Definition of a Gel
    • Film Imperfections or defects developed
    during forming due to disturbances in
    the polymer flow
    Classification of Film
    Imperfections
    • Contamination
    • Un-melt
    • Un-mix
    • Thermal degradation
    Origins
    Gels can be created or introduced
    during
    • Polymerization
    • Equipment-Screw Design
    • Fabrication
    Contamination
    Gauge Bands/Gels
    • Contamination
    – Fiber
    Fiber Gel After Melting

    Gel

    Polarized light (w/ 1/4 filter)


    Gauge Bands/Gels
    • Contamination
    – Fiber
    – Resin Contamination
    Resin Contamination
    LDPE EVA
    • Polyolefin • Acid functional
    • More Crystalline groups
    • Thermally stable • Less Crystalline
    • Adhesion through • Not thermally stable
    oxidation • Adhesion through
    • 600°F - 630°F vinyl acetate groups
    processing temperature
    • 450°F processing
    temperature
    Cross Contamination Solutions
    • Better Housekeeping
    • Better purging
    • Work with resin companies
    Gauge Bands/Gels
    • Contamination
    – Fiber
    – Resin Contamination
    • Un-melt and un-mix
    Hot Stage Microscopy
    • Slowly heat sample to above melting
    point.
    • Transmit light through cross-polarized
    filters.
    • Observe melting point of film/gel and
    note any birefringence effects.
    Unmixed Gel Characterization

    50°C 150°C 50°C

    Unmixed Gel
    Gauge Bands/Gels
    • Contamination
    – Fibers
    – Cross contamination w/other Polymers
    • Un-melt & un-mixed
    – Bad Concentrate
    Mixing
    Master Batch Concentrates
    • Compatibility of base resin
    • quality of dispersive mixing
    – agglomerates
    Gauge Bands/Gels
    • Contamination
    – Fibers
    – Cross contamination w/other Polymers
    • Un-melt & un-mixed
    – Bad Concentrate
    – Blends with different melting rate
    Mixing
    Polymer Blends and Additives
    • Thermodynamic compatibility of
    components (conductivity)
    • Large differences in melting points of
    blend components
    • Large viscosity ratios between minor
    and major components
    Gauge Bands/Gels
    • Contamination
    – Fibers
    – Cross contamination w/other Polymers
    • Un-melt & un-mixed
    – Bad Concentrate
    – Blends with different melting rate
    – Fluff
    Contiguous Solids Melting
    Gauge Bands/Gels
    • Contamination
    – Fibers
    – Cross contamination w/other Polymers
    • Un-melt & un-mixed
    – Bad Concentrate
    – Blends with different melting rate
    – Fluff
    – Bad temperature profile
    Gauge Bands/Gels
    • Contamination
    – Fibers
    – Cross contamination w/other Polymers
    • Un-melt & un-mixed
    – Bad Concentrate
    – Blends with different melting rate
    – Fluff
    – Bad temperature profile
    – Inconsistent granular size
    Gauge Bands/Gels
    • Contamination
    – Fibers
    – Cross contamination w/other Polymers
    • Un-melt & un-mixed
    – Bad Concentrate
    – Blends with different melting rate
    – Fluff
    – Bad temperature profile
    – Inconsistent granular size
    – Screw design
    Screw Design
    • Improper design for the resin can
    contribute to:
    – SBB causing encapsulation of un-melt
    solids
    – SBB also causes non uniform mixing
    history
    – Not providing enough shear to melt resin
    Observed Solid Bed Break-up

    MELT
    POOL

    CONVENTIONAL
    SCREW
    Gauge Bands/Gels
    • Contamination
    – Fiber
    – Resin Contamination
    • Un-melt and un-mix
    • Thermal degradation
    Polymer Degradation is a
    Function of
    Time Temperature

    Shear Conditions

    All polymers degrade as a function of


    time, temperature, and shear conditions
    Degradation Gels
    Types of Polymer Degradation
    • Thermal - High temperatures
    • Chain Scission - High stress fields
    • Cross-linking - Un-saturation
    • Oxidation - Oxygen
    Example of crosslinking
    m

    • Ethylene Vinyl Acetate (EVA) O


    C O
    – -(CH2-CH2)m-(CH-CH3COO)- CH3

    • Temperature causes
    decarboxylation which result in
    releasing Acetate, CO2, and primary
    m

    free radicals
    m
    O
    m

    C O
    O CH3 O*
    Heat
    C O O
    FreeC Radical
    CH3 CH3
    EVA Degradation
    • Creates acetic acid at LDPE process
    temperatures.
    EVA - Effect of Over Heating...
    m

    • Ethylene Vinyl Acetate (EVA) O


    C O
    – -(CH2-CH2)m-(CH-CH3COO)- CH3

    • Temperature causes
    decarboxylation which result in
    releasing Acetate, CO2, and primary
    m

    free radicals
    m
    O
    m

    C O
    O CH3 O*
    Heat
    C O O
    FreeC Radical
    CH3 CH3
    Side Reaction
    m m

    m
    m

    +
    O* O O
    C O C O C O
    CH3 CH3 CH3
    Lightly Crosslinked Gel

    50°C 150°C 50°C

    Melt Lightly crosslinked


    What does crosslinked mean?
    • Too much energy provided to the
    polymer.
    Too much heat
    • Shear
    Cross
    Cross Section
    Section of
    of Single-Screw
    Single-Screw
    Extruder
    Extruder

    state of material: fluid fluid/solid solid

    melt generator melting/plasticatin conveying


    g
    gear
    box

    Z6-----------------------------------------------------------------------------Z1
    pressure
    output and metering zonetransition
    utilize or feed zone drive
    alternative-mixing
    compression
    melt generator
    Too much heat
    • Shear
    • Heaters
    Too much heat
    • Shear
    • Heaters
    – T/C not in bottom of well
    T/C Location
    Too much heat
    • Shear
    • Heaters
    – T/C not in bottom of well
    • Extruder Residence time
    Heat in/Cold HEAT TRANSFER IN
    out AN EXTRUDER
    heaters-coolers

    cooling Mechanical

    Enthalpy of screw Energy

    Resin
    drive
    Gel Hang-up at adapter
    Gauge Bands/Gels
    • Fibers/Contamination
    • Cross contamination w/other Polymers
    • Un-melt
    • Cross-Linked
    • Oxidation
    Oxidized Gel

    Gel

    Oxidized Gel at 130 C with polarized light (w/ 1/4 filter)


    Oxidized Gels
    • Formed very rapidly in the presence of
    oxygen
    • Corrective Action
    – Improve stabilizer package
    – Reduce exposure to oxygen during
    processing
    – Reduce Temperature
    Oxidation of resin
    • Incorrect shut down (not capping die)
    • Incorrect start-up with cleaned die
    Gauge Bands/Die Lines
    • Hang up of gels
    • Temperature variation
    • Automatic die control
    • Static Mixer position
    • Hang Ups in flow path
    Gel Hang-up at adapter
    Solving Gel Problems
    • Identify the source of the Imperfection
    – Un-melt
    – Degradation (Cross link or Oxidized)
    – Contamination (Dust, Dirt, Fiber)
    – Agglomeration (Color, Additives)
    • Find the Source
    – Resin
    – Equipment
    – Blends/Additives
    Tools to detect gel problems
    • Hot stage microscopy
    • IR analysis
    • Chemical Analysis
    • DSC unit
    Thank You
    PRESENTED BY

    Lou Piffer
    Senior Sales Engineer
    Davis-Standard, LLC

    Please remember to turn


    in your evaluation sheet...

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