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![Page 1: Extrusion Lamination of Polywoven Bags - · PDF fileExtrusion Lamination of Poly-woven Bags An over-view of primers and resins Jessica Bodine – Mica Corporation. IOPP Technical Bag](https://reader034.vdocument.in/reader034/viewer/2022051405/5a7901907f8b9a43758c7d28/html5/thumbnails/1.jpg)
Extrusion Lamination of Poly-woven Bags
An over-view of primers and resins
Jessica Bodine – Mica CorporationIOPP Technical Bag Committee MeetingJanuary 20th, 2009
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The Science of Adhesion
Two Types of BondingChemical
&Mechanical
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Polypropylene Woven: Basic Lamination –“Mechanical” Adhesion
OPP Film
PP Extrudate
PP Woven
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What is a Bag With-out printing?
Surface Printing does not interfere with extrudate adhesionBenefits of reverse printing:• Gloss• Clarity• Scuff Resistance• Moisture Resistance
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Reverse Printed Lamination
INKPP Extrudate
PP Woven
OPP Film
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What happens next?Ink does not stick to OPP film OR extrudate:
Failure will be at weakest interface
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Ink Needs “Chemical” Adhesion
Corona not only provides wet-out of ink –but chemical “anchors” for ink
PP Extrudate
PP Woven
Ink
TreatedOPP
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Corona Treatment
Watt-Density = Power /(area x time)US Units: W/(ft2/minute)
[KW setting x 1000] / [Line Speed (ft/min) x width (ft)]
Example:
Treater output = 3.0kW; line speed = 450 fpm; Treater width = 5 ft
The watt-density is: (3.0 x1000)/(450 x 5) = 1.7 W/(ft2/min)
Important: You must determine optimum watt-density for each film andfor each set of running conditions.
Some starting suggestions: BOPP films: 3.0 – 4.0 WDOPET films: 1.5 – 2.0 WDBON films: 0.5 – 1.5 WD(metric units are factor of 10 higher)
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What Happens next?
Ink now sticks great to OPP:Makes ink/extrudate interface appear even weaker
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Two part Solution:
Part 1: Primers
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What is a Primer?
Surface modifier
increases energy
cleans, removes contaminants
adds reactive sites
Facilitates “wet-out” of secondary coating
Provides adhesion between substrate and coating/extrudate
Enhances chemical resistance
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Mica Water-Based Primers for Film When Using Polyolefin Extrudate
Cross-linked (!) Polyethylene Imine (PEI)
Mica A-131-X – 5% solids, standard of the industry, pH 10.5, easy to use and clean-up, components are FDA CFR 175.105
Mica H-760-A – 12% solids, less shipping, more attention to dilution, easy clean-up and components are FDA CFR 175.105
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How do you apply a Primer?
• Smooth Roll Applicator
• Gravure or Anilox Applicators
• Mayer Rod (Wire Wound) Applicator
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How do you apply a Primer?
Smooth Roll ApplicatorHard rubber impression roll
• 90 durometer• Does not have to be undercut
Low compression• Approximately ¼ inch (6 mm)
Vary application weight by;• Applicator roll speed• Primer dilution recipe
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How do you apply a Primer?
Smooth Roll (3) Applicator (Indirect)
Backup RollWeb
Primer Reservoir
Transfer Roll
Pick-up Roll
Flooded Nip
Flooded Nip
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Smooth Roll Applicator (Direct)
How do you apply a Primer?
Flooded Nip
Rubber Impression RollWeb
Smooth Rubber Pickup Roll
Primer Reservoir
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How do you apply a Primer?Direct Gravure Applicator
>
Chambered doctor blade
Primer reservoir
Gravure Roll
Backup RollWeb
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How do you apply a Primer?
Gravure Applicator – SpecificationsTo deliver target wet/dry weight;
Specify a cell volume - not a line count.Example: PEI type primer for film substrate
Dilute primer 1:1
Apply 0.02 dry lbs/ream
Many possible configurations:
Direct forward gravure, 180 pyramid, 3.2 bcm
Direct forward gravure, 360 pyramid, 3.7 bcm
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How do you apply a Primer?
Gravure Applicator – Materials•Ceramic
•Long service life•Prone to clogging•Add 15 – 20% cell volume to
compensate•Chrome
•Easier to clean•Shorter service life
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Mayer Rod ApplicatorWire Wound Coating Rod
Space between wire windings determine amount delivered (0.003" - 0.060" in 0.001" increments).
How do you apply a Primer?
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How do you apply a Primer?
Steps to follow;1)Treat
Corona, Flame2)Apply
Smooth roll, Gravure, Flexo3)Dry
Hot, circulating air; infraredFlame (paper only)
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How do you apply a Primer?
Ensure Proper Coatweight
Recommended Range is: 0.02 – 0.03 dry lbs/ream% Solids by refractometer or gravimetric oven test.Monitor coatweight by consumption of primer.Use Mica “Color-Chip” Stain TestPrimer coating uniformity;
a) Water soluble optical brightener with a UV lamp.b)Eosin stain testing and “Color-Chip”/Colorimeter.
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How do you apply a Primer?
Ensure Complete Drying
a) Drying MICA A-131-X is relatively easy.
b) Oven airflow is equally important as the exit web temperature.
c) Recommended Exit Web Temperature: 140oF – 180oF
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Primers and reactive sites
Primer adds reactive sites to the ink?
But what about the extrudate?
= primer
PP Extrudate
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Part 2
The Resins
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Polyethylene
Oxidized in extrusion processReactive sites form chemical bonds with primersDoes not stick to polypropylene woven (will stick the HDPE though)Does not have strength, heat and grease resistance of polypropylene
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Polypropylene
“Inert” chemical nature – does not oxidize during extrusionNo reactive sites for chemical reaction (inks OR primers)Does “mix” with PP poly-woven (mechanical)Tough, strong, excellent moisture and grease resistance
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Maleic Anhdride Adhesive Resins
Known to give adhesion as tie-layer (costly and requires co-extrusion)Mica has discovered that “MAH” concentrates can be blended in polypropyleneMica water-based primers have perfect chemistry for reaction with MAH – serves as the reactive site for the extrudate
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Maleic Anhydride Concentrate Considerations
Backbone (concentrate base resin) needs to be compatible with resin to be extrudedNeeds 1-2% maleic anhydride (or equivalent) in order to be diluted to 0.2% total anhydride content in final blendBlending 10 – 20% of material must not interfere with extrusion properties (melt strength, neck-in etc.)
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Materials
Resin 1: DuPont Bynel 50E803 Resin 2: Chemtura Polybond 3000Resin 3: Arkema Orevac CA 100
Concentrates were blended into polypropylene so that the final MAH concentration was 0.20%
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Finished Structure
= primer = MAH resin
Chemical reactions at every interface = destructive bonding
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Steps to Making Poly-woven Lamination
1. OPP with 54 or higher dyne level2. Print3. Prime with 0.02 dpr cross-linked PEI4. Dry thoroughly5. Extrude with PP + 15-20% MAH
concentrate6. Laminate PP woven
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Some Additional ConsiderationsPP base resin (extrusion grade!)• Homo-polymer• Co-polymer• Added polyloefin for run-ability • Final mix should be at least 70% PP
Slip additives in OPP filmCohesive strength of the ink• Ink chemistry• Coverage• Drying• In-line/out of line priming
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Experimental
Primer Resin Bonding
Yes PP only zero
No PP + resin one zero
Yes PP + resin one 60% ink removal
No PP + resin two zero
Yes PP + resin two 80% ink removal
No PP + resin three zero
Yes PP + resin three 60% ink removal
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Discussion of Results
Strength of structure will be strength of the weakest interfaceIn this case – ink cohesion was weakest Primer can be used under the inks when this is the issue (still needs corona treatment)
OPP/”T”/primer/ink/primer/PP+MAH/woven
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Contact Information
Jessica BodineMica Corporation9 Mountain View DriveShelton, CT 06484(203) [email protected]
THANK YOU!