Plastic drawing response in the biaxially oriented polypropylene (BOPP) process: polymer structure and film casting effects

Processing isotactic polypropylene (iPP) from cast film into biaxially oriented polypropylene (BOPP) involves plastic drawing of a semi-crystalline morphology in the melting range of iPP, where the crystal phase is reduced and the polymer has high mobility. The literature claims that plastic drawing in general and at elevated temperatures in particular depends predominantly on the structure of the amorphous entanglement network. We investigated this aspect using laboratory-scale biaxial drawing experiments. Three iPP homopolymer types differing in chain isotacticity and molecular weight distribution were extruded into 200-μm-thick primary sheets using 10 different extrusion settings. The sheets were biaxially drawn on a laboratory stretcher at 157°C and 160°C, recording the respective stress-strain curves. These curves were evaluated according to a rubber elasticity model to obtain the network modulus, GN, of the entanglement network. The effects of iPP type, the extrusion parameters, the resulting cast film properties, and the draw temperature on GN are discussed.

In situ simultaneous measurement of stress, retardation, and three-dimensional refractive indexes during biaxial stretching experiments under various preheating times

An evaluation method for the stretchability of a biaxially oriented film during the stretching process was recently developed using an in situ measurement test machine. Stress, retardation, three-dimensional refractive indexes, light-scattering image, and birefringence distribution of films could be obtained in a short time. This stretching test machine was applied to examine the film stretchability of both semicrystalline polymers, such as polypropylene, and noncrystalline polymers, such as polystyrene, under various preheating times. From the measurements, the stress of semicrystalline polymers increased with increasing preheating times before stretching the film. However, the stress of noncrystalline polymers did not increase with increasing preheating times. This means that semicrystalline polymer is required to set up an optimum stretching condition of the preheating time for a satisfactory biaxially oriented film. Furthermore, the birefringence distribution and thickness uniformity of the stretched film were measured simultaneously. It was found that the stretchability of polypropylene and polystyrene films could be evaluated with a small piece of the sample using the biaxial stretching test machine.

Structural Evolution of Two-Phase Blends of Polycarbonate and PMMA by Simultaneous Biaxial Stretching

We investigated the structural evolution of the two-phase blends of polycarbonate (PC) and poly(methyl methacrylate) (PMMA) at various blend compositions by simultaneous biaxial stretching, using optical microscopy and SEM observation. The spherical PMMA domains and PC matrix of 30/70 PC/PMMA were enlarged uniformly at the all in-plane direction, while the anisotropic-shaped co-continuous structure in 50/50 PC/PMMA was deformed to a crosshatched structure by the in-plane bimodal orientation. In 70/30 PC/PMMA, the phase inversion was found to occur by simultaneous biaxial stretching; that is, the spherical PMMA domains were changed to a crosshatched matrix by the in-plane bimodal orientation due to coalescence of the PMMA domains during the stretching. Owing to the phase inversion, the surface hardness estimated by the pencil hardness test became harder, from 2B to 2H, increasing the strain from 1.0 to 2.0.

Development of a biaxial stretching test machine and its applications

The evaluation method for a biaxially oriented film was developed using in-situ measurement during the stretching process. It can obtain basic data such as stress-strain curves, birefringence, light scattering, three dimensional refractive indexes and birefringence distribution. Stress and strain as functions of stretching speed and stretching temperature, as well as the deformation of spherulite of semi-crystalline polymer can be obtained by measuring the birefringence and light scattering during the biaxial stretching process with a small piece of polymer sample. The experimental results show the stress, retardation and three dimensional molecular orientations behavior during the simultaneous biaxial stretching and the sequential biaxial stretching process. Stretchability, thickness uniformity and spherulite size can be obtained simultaneously. In this paper, advantages and details of the newly developed system will be discussed with some experimental data.