Improved Properties and Cost Efficiencies of     Cyclic Olefin Copolymer Enhanced               Forming Films             ...
What Are Cyclic Olefin Copolymers (COC)?  The cyclic olefin copolymer (COC) molecule is a  linear chain of small CH2-CH2 l...
What Are COC Properties & Attributes?      Glass transition temperatures, °C(°F)     Glass Clear, Transparent      70 - 18...
Outline          Why Use COC in Forming Films?          Thermoforming Properties:             Gauge Distribution          ...
Why Use COC in Thermoforming?        Improve many physical properties        Impart new functionality, such as barrier & h...
Thermoforming Properties:     Gauge Distribution                            TOPAS Advanced Polymers                       ...
Thermoforming Methodology     Macron Thermoformer        Modified Blister Packaging Machine        Pressure, Not Vacuum Fo...
Macron Thermoforming Machine                               TOPAS Advanced Polymers                               A member ...
Forming Temperature                                                                                Optimal                ...
Thermoforming: Gauge Distribution       Measure Formed Cavity Gauge with Magna-Mike           6 Points (4 Wall & 2 Bottom)...
Measurement Locations in MD and TD                                     TOPAS Advanced Polymers                            ...
Gauge Variation: Film Structure & Cost                                                          Optimal Forming      CV   ...
Thermoforming Properties: Volume Retention (“Snapback”)                                 TOPAS Advanced Polymers           ...
Cavity Support Tool: Volume RetentionAdjustable Bottom Support Can Accommodate Multiple Cavity Depths     Fill the Secured...
Volume Retention of Formed Cavities                                     Octene LLDPE + 8007F-04    Octene LLDPE + 8007F-10...
Formed Cavities: COC & Octene LLDPE   0             10             15             20            30 % COC        Incrementa...
Retained Volume: Film Structure & Cost                                                            Retained Material       ...
Thermoforming Properties:      Crush Resistance                            TOPAS Advanced Polymers                        ...
Crush Resistance Testing Method Formed cavities are crushed in between two parallel plates                                ...
Crush Resistance of Formed Cavities:                            Displacement (mm) at 1.9 lbf                              ...
Crush Resistance: Film Structure & Cost                                                             Crush                 ...
Thermoforming Properties:  Corner Puncture Resistance                               TOPAS Advanced Polymers               ...
Cavity Puncture Tool: Bottom & Corner         Flexible Tool Configuration Enables Accurate     Measurement of Puncture Res...
Corner Puncture: Film Structure & Cost                                                          Formed   Corner           ...
Comparatives & Conclusions                             TOPAS Advanced Polymers                             A member of Dai...
Monolayer COC vs. 5-Layer Nylon                                               5.9-mil PE/Tie/PA/Tie/PE              6-mil ...
Monolayer COC vs. 5-Layer Polyolefin                                             6-mil PP/LLDPE+LDPE/PP              4.7 m...
5-Layer COC vs 3-Layer Ionomer                                               12-mil LDPE/Ionomer/LDPE             6-mil b-...
COC Benefits For Forming Films        Improve Thermoformability & Enhance Package        Integrity with Less Gauge Variati...
Acknowledgments    Thermoforming Team:       Adam Barton, Wolfram Goerlitz, Randy Jester,       Tim Kneale, Bernd Sparenbe...
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Flexible Forming Webs: SPE ANTEC 2007

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Transcript of "Flexible Forming Webs: SPE ANTEC 2007"

  1. 1. Improved Properties and Cost Efficiencies of Cyclic Olefin Copolymer Enhanced Forming Films Paul D. Tatarka SPE Annual Technical Conference May 7, 2007 TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  2. 2. What Are Cyclic Olefin Copolymers (COC)? The cyclic olefin copolymer (COC) molecule is a linear chain of small CH2-CH2 links randomly interspersed with large bridged ring elements It cannot fold up to make a regular structure, i.e., a crystallite NB NB NB NB COC has no crystalline melting point, but only a glass transition temperature, Tg , at which the polymer goes from “glassy” to “rubbery” behavior TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  3. 3. What Are COC Properties & Attributes? Glass transition temperatures, °C(°F) Glass Clear, Transparent 70 - 180 (154 – 356) Sterilizable via Steam, EtO, Modulus of elasticity, N/mm2 (kpsi) gamma, beta (E-beam) 2600 – 3200 (380 – 460) Resistant to Alcohols, Tensile strength, N/mm2 (kpsi) Acids, Bases, Polar 66 (10) Solvents Density, g/cm3 High Purity, Low 1.02 Extractables Water uptake, % Low Water Transmission < 0.01 Rate (WVTR) WVTR, g × mm/m2 (mil/100 in2) × day 0.02 - 0.04 (0.05 – 0.10) Biocompatible Halogen-free TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  4. 4. Outline Why Use COC in Forming Films? Thermoforming Properties: Gauge Distribution Crush Resistance Volume Retention (“Snapback”) Corner Puncture Comparative (Spider Charts) Nylon Polyolefin Ionomer Benefits & Conclusions TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  5. 5. Why Use COC in Thermoforming? Improve many physical properties Impart new functionality, such as barrier & heat resistance; and capability, such as deep draw Improve thermoformability Improve package performance & durability Enable downgauging to satisfy source reduction initiatives Reduce cost of forming film TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  6. 6. Thermoforming Properties: Gauge Distribution TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  7. 7. Thermoforming Methodology Macron Thermoformer Modified Blister Packaging Machine Pressure, Not Vacuum Forming Heated Plug Assist (60oC; Slow Speed ~1.0 sec) Forming Tool Dimension: 2.5 x 4.0 Inches 1-Inch Depth of Draw Areal Draw Ratio (Ra): 1.87:1 0.5-inch Corner Radii Thermoforming Experimental Design Matrix (Forming Window) Temperature: Low, Medium & High Cycle Time: 10, 14 & 18 cycles per minute Forming Pressure: 10, 20 & 30 psi 13 Conditions Evaluated Per Film Structure TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  8. 8. Macron Thermoforming Machine TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  9. 9. Forming Temperature Optimal Forming Forming TOPAS® Temperature Temperature Gauge Film Description COC (%) Range (oC) (oC) (mil) o-LLDPE + 15% 8007F-100 (1,C) 15 90, 95, 100 95 6.0h-m-LLDPE + LDPE + 12% 9506 + 3% 6013 (1,C) 15 95, 100, 105 100 4.7 o-LLDPE + 20% 8007F-100 (1,C) 20 100, 105, 110 105 6.0 m-h-LLDPE + LDPE + 9506 Discrete (7,B) 24 85, 90, 95, 100 90 4.7m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 90, 95, 100, 105 95 6.0m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 90, 95, 100 90 4.0 o-LLDPE + 30% 8007F-100 (1,C) 30 100, 105, 110 105 6.0b-LLDPE/ 8007F-100 /EVA/8007F-100/b-LLDPE (5,C) 30 85, 95, 100, 105 105 6.0 b-LLDPE + 30% 8007F-100 (1,C) 30 95, 100, 105 100 6.0 LDPE/Ionomer/LDPE (3,C) 0 80, 85, 90, 95 90 6.0 LDPE/Ionomer/LDPE (3,C) 0 80, 85, 90, 100 85 12.0 rPP/LLDPE+LDPE/rPP (5,C) 0 90, 100, 110 110 6.0 PE/tie/PA/tie/PE (5,B) 0 85, 90, 95, 100 90 5.9Forming Temperatures Are Similar For COC & Non-COC FilmsForming Temperatures Depend On Tg Of COC, Gauge & Other Polymers TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  10. 10. Thermoforming: Gauge Distribution Measure Formed Cavity Gauge with Magna-Mike 6 Points (4 Wall & 2 Bottom) Machine Direction 6 Points (4 Wall & 2 Bottom) Transverse Direction 5 Cavities Per Forming Condition 60 Measured Points Coefficient of Variation (CV) Statistic Used to Quantify Gauge Distribution Ratio of Standard Deviation & Mean Describes Percentage of Gauge Variation in the Part “Optimal” CV Identified by the Forming Conditions Yielding Lowest CV Design Matrix or Forming Window CV Average CV from ALL Forming Conditions TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  11. 11. Measurement Locations in MD and TD TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  12. 12. Gauge Variation: Film Structure & Cost Optimal Forming CV Material TOPAS® Forming Matrix CV Difference Cost Gauge Film Description COC (%) CV (%) (%) (%) ($/MSI) (mil) o-LLDPE + 15% 8007F-100 (1,C) 15 19.5 22.1 2.6 $0.206 6.0h-m-LLDPE + LDPE + 12% 9506 + 3% 6013 (1,C) 15 13.5 16.2 2.7 $0.170 4.7 o-LLDPE + 20% 8007F-100 (1,C) 20 17.7 21.5 3.8 $0.217 6.0 m-h-LLDPE + LDPE + 9506 Discrete (7,B) 24 20.5 23.2 2.7 $0.190 4.7m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 26.1 28.5 2.4 $0.245 6.0m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 24.6 26.4 1.8 $0.163 4.0 o-LLDPE + 30% 8007F-100 (1,C) 30 15.8 16.8 1.0 $0.238 6.0b-LLDPE/ 8007F-100 /EVA/8007F-100/b-LLDPE (5,C) 30 16.9 17.2 0.3 $0.215 6.0 b-LLDPE + 30% 8007F-100 (1,C) 30 13.4 15.6 2.2 $0.218 6.0 LDPE/Ionomer/LDPE (3,C) 0 8.3 13.7 5.4 $0.232 6.0 LDPE/Ionomer/LDPE (3,C) 0 10.2 13.9 3.7 $0.464 12.0 rPP/LLDPE+LDPE/rPP (5,C) 0 36.9 45.0 8.1 $0.172 6.0 PE/tie/PA/tie/PE (5,B) 0 17.8 22.7 4.9 $0.243 5.9Gauge Variation Narrows Considerably Between The Best And All Other Forming Conditions For Most COC Films, Suggesting COC Provides Robust Forming WindowBoth COC And Ionomer Forming Films Have Low Gauge VariationExcellent Forming Is Maintained After Downgauging TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  13. 13. Thermoforming Properties: Volume Retention (“Snapback”) TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  14. 14. Cavity Support Tool: Volume RetentionAdjustable Bottom Support Can Accommodate Multiple Cavity Depths Fill the Secured Cavity with Water and Measure Its Volume TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  15. 15. Volume Retention of Formed Cavities Octene LLDPE + 8007F-04 Octene LLDPE + 8007F-100 Butene LLDPE + 8007F-100 LDPE/Ionomer/LDPE Reference 102 Volume Retention (%) 100 98 96 94 . 92 90 88 86 0 10 15 20 30 Reference Weight Percent COC Addition of 15% or More COC Significantly Improves Dimensional Stability And Almost Eliminates Cavity Shrinkage TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  16. 16. Formed Cavities: COC & Octene LLDPE 0 10 15 20 30 % COC Incremental Addition of COC Clearly Shows the Progressive Improvement in Cavity Appearance TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  17. 17. Retained Volume: Film Structure & Cost Retained Material TOPAS® Volume Cost Gauge Film Description COC (%) (%) ($/MSI) (mil) o-LLDPE + 15% 8007F-100 (1,C) 15 96.7 $0.206 6.0h-m-LLDPE + LDPE + 12% 9506 + 3% 6013 (1,C) 15 91.8 $0.170 4.7 o-LLDPE + 20% 8007F-100 (1,C) 20 100.0 $0.217 6.0 m-h-LLDPE + LDPE + 9506 Discrete (7,B) 24 89.4 $0.190 4.7m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 86.8 $0.245 6.0m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 89.9 $0.163 4.0 o-LLDPE + 30% 8007F-100 (1,C) 30 98.2 $0.238 6.0b-LLDPE/ 8007F-100 /EVA/8007F-100/b-LLDPE (5,C) 30 94.8 $0.215 6.0 b-LLDPE + 30% 8007F-100 (1,C) 30 98.0 $0.218 6.0 LDPE/Ionomer/LDPE (3,C) 0 93.9 $0.232 6.0 LDPE/Ionomer/LDPE (3,C) 0 88.7 $0.464 12.0 rPP/LLDPE+LDPE/rPP (5,C) 0 91.5 $0.172 6.0 PE/tie/PA/tie/PE (5,B) 0 91.3 $0.243 5.9COC-LLDPE Films Exhibit Almost No Shrinkage Or Snap-BackDowngauging Does Not Compromise Retained VolumeRetained Volume May Be Reduced By LDPE TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  18. 18. Thermoforming Properties: Crush Resistance TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  19. 19. Crush Resistance Testing Method Formed cavities are crushed in between two parallel plates TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  20. 20. Crush Resistance of Formed Cavities: Displacement (mm) at 1.9 lbf Octene LLDPE + 8007F-04 Octene LLDPE + 8007F-100 Butene LLDPE + 8007F-100 LDPE/Ionomer/LDPE Reference 30.00. 25.00Displacement (mm) 20.00 15.00 10.00 5.00 0.00 0 10 15 20 30 Reference Weight Percent COCCOC Addition Increases Crush Resistance By Reducing The Amount Of Cavity Deflection Required to Reach 1.9 lbf Load TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  21. 21. Crush Resistance: Film Structure & Cost Crush Resistance Material ® TOPAS (Deflection) @ Cost Gauge Film Description COC (%) 1.9 lbf mm ($/MSI) (mil) o-LLDPE + 15% 8007F-100 (1,C) 15 23.2 $0.206 6.0 h-m-LLDPE + LDPE + 12% 9506 + 3% 6013 (1,C) 15 26.8 $0.170 4.7 o-LLDPE + 20% 8007F-100 (1,C) 20 19.5 $0.217 6.0 m-h-LLDPE + LDPE + 9506 Discrete (7,B) 24 24.7 $0.190 4.7 m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 13.8 $0.245 6.0 m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 27.5 $0.163 4.0 o-LLDPE + 30% 8007F-100 (1,C) 30 15.6 $0.238 6.0 b-LLDPE/ 8007F-100 /EVA/8007F-100/b-LLDPE (5,C) 30 21.6 $0.215 6.0 b-LLDPE + 30% 8007F-100 (1,C) 30 11.8 $0.218 6.0 LDPE/Ionomer/LDPE (3,C) 0 24.6 $0.232 6.0 LDPE/Ionomer/LDPE (3,C) 0 11.8 $0.464 12.0 rPP/LLDPE+LDPE/rPP (5,C) 0 24.3 $0.172 6.0 PE/tie/PA/tie/PE (5,B) 0 21.7 $0.243 5.9COC Improves Crush Resistance of Formed TraysDowngauged COC Films Match Peformance of Non-COC FilmsDowngauged COC Films Offers Similar Protection, But At Less Cost TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  22. 22. Thermoforming Properties: Corner Puncture Resistance TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  23. 23. Cavity Puncture Tool: Bottom & Corner Flexible Tool Configuration Enables Accurate Measurement of Puncture Resistance of Formed Cavities TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  24. 24. Corner Puncture: Film Structure & Cost Formed Corner Formed Corner Puncture Material Corner TOPAS® Puncture Retention Cost Gauge Gauge Film Description COC (%) (lb) (%) ($/MSI) (mil) (mil) o-LLDPE + 15% 8007F-100 (1,C) 15 5.7 82.9 $0.206 2.0 6.0h-m-LLDPE + LDPE + 12% 9506 + 3% 6013 (1,C) 15 6.2 69.7 $0.170 1.1 4.7 o-LLDPE + 20% 8007F-100 (1,C) 20 6.2 79.0 $0.217 2.0 6.0 m-h-LLDPE + LDPE + 9506 Discrete (7,B) 24 6.1 77.1 $0.190 1.4 4.7m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 8.2 78.8 $0.245 3.1 6.0m-h-LLDPE + LDPE + 9506/5013 Discrete (7,B) 25 6.7 94.4 $0.163 2.3 4.0 o-LLDPE + 30% 8007F-100 (1,C) 30 8.5 96.4 $0.238 2.0 6.0b-LLDPE/ 8007F-100 /EVA/8007F-100/b-LLDPE (5,C) 30 5.9 64.0 $0.215 1.6 6.0 b-LLDPE + 30% 8007F-100 (1,C) 30 8.3 95.3 $0.218 1.8 6.0 LDPE/Ionomer/LDPE (3,C) 0 8.3 81.6 $0.232 1.8 6.0 LDPE/Ionomer/LDPE (3,C) 0 10.2 57.5 $0.464 4.0 12.0 rPP/LLDPE+LDPE/rPP (5,C) 0 5.0 56.0 $0.172 1.2 6.0 PE/tie/PA/tie/PE (5,B) 0 10.2 81.0 $0.243 1.5 5.9Corner Puncture And Retention Improve With Addition Of COCFilms With 25 to 30 Percent COC Are As Puncture Resistant As Ionomeric FilmCOC Films Can Be Downgauged Without Sacrificing Puncture Resistance TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  25. 25. Comparatives & Conclusions TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  26. 26. Monolayer COC vs. 5-Layer Nylon 5.9-mil PE/Tie/PA/Tie/PE 6-mil o-LLDPE w/30% 8007F-100 (=) Cost ($/MSI) 120 (-) Formed Corner Puncture (lb) (=) Gauge (mil) 100 80 (-) Formed Cavity Puncture (lb) 60 (=) Haze (%) 40 20(+) Formed Cavity Gauge Variation (%) 0 (-) Gloss (60 Degree) (-) Retained Volume (%) (-) MD Modulus (ksi) (-) TD Tensile Strength (ksi) (-) TD Modulus (ksi) (-) MD Tensile Strength (ksi) TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  27. 27. Monolayer COC vs. 5-Layer Polyolefin 6-mil PP/LLDPE+LDPE/PP 4.7 mil h-LLDPE w/15% 9506 & 6013 (=) Cost ($/MSI) 160 (+) Formed Corner Puncture (lb) 140 (+) Gauge (mil) 120 100 (=) Formed Cavity Puncture (lb) 80 (+) Haze (%) 60 40 20(+) Formed Cavity Gauge Variation (%) 0 (+) Gloss (60 Degree) (=) Retained Volume (%) (+) MD Modulus (ksi) (+) TD Tensile Strength (ksi) (+) TD Modulus (ksi) (-) MD Tensile Strength (ksi) TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  28. 28. 5-Layer COC vs 3-Layer Ionomer 12-mil LDPE/Ionomer/LDPE 6-mil b-LLDPE/COC/EVA/COC/b-LLDPE (+) Cost ($/MSI) 350 (-) Formed Corner Puncture (lb) (+) Gauge (mil) 300 250 200 (-) Formed Cavity Puncture (lb) (+) Haze (%) 150 100 50 (-) Formed Cavity Gauge Variation (%) 0 (+) Gloss (60 Degree) (-) Retained Volume (%) (+) MD Modulus (ksi) (=) TD Tensile Strength (ksi) (+) TD Modulus (ksi) (=) MD Tensile Strength (ksi) TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  29. 29. COC Benefits For Forming Films Improve Thermoformability & Enhance Package Integrity with Less Gauge Variation & Good Dimensional Stability Enable Downgauging to Reduce Material Cost Improve Most Physical Properties, Including Stiffness, Strength, Impact Resistance & Optics Design Recommendations: LLDPE – No Restrictions LDPE – Minimize in LLDPE-COC Blends Any questions? TOPAS Advanced Polymers A member of Daicel/Polyplastics Group
  30. 30. Acknowledgments Thermoforming Team: Adam Barton, Wolfram Goerlitz, Randy Jester, Tim Kneale, Bernd Sparenberg U. of Cincinnati Co-Op Students: John Guzowski, Elizabeth Jeffries, Shery Kern, Angela Martin, Amy Riesenberg TOPAS® Cyclic Olefin Copolymer (COC) Your Clear Advantage questions? Any in Thermoforming. TOPAS Advanced Polymers A member of Daicel/Polyplastics Group

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