Film and Sheet

Film and sheet are defined as flat unsupported sections of a plastic resia whose thickness is very thin ia relation to its width and length. Films are generally regarded as being 0.25 mm or less, whereas sheet may range from this thickness to several centimeters thick. Film and sheet may be used alone ia their unsupported state or may be combined through lamination, coextmsion, or coating. They may also be used in combination with other materials such as paper, foil, or fabrics. 

Film and sheeting materials test methods have been standardized by ASTM, DIN, and others. As with all materials, the test specimens must be carefiiUy prepared and conditioned. Thin-film specimens are vulnerable to nicks and tears which mar the results. Moisture and temperature can affect some materials. Common test methods are Hsted in Table 1. 

Stiffness of the films and sheeting can be measured as the tensile modulus of elasticity. Droop or drape tests may be used, particularly for multilayer products. The stiffness is strongly influenced by thickness (to the third power) and temperature, and is important to the processing of film in printing, coating, or end use appHcations where it affects the "hand" of the product. 

Tables 2—5 Hst some typical properties or ranges of properties for the more common film and sheet products. Although these values are good for comparative purposes, actual performance tests are best to determine suitabiHty for use. Properties of multiple-layer films or sheets in laminar stmctures cannot always be predicted from values for the individual polymer layers. Use conditions of stress, temperature, humidity, and light exposure all strongly influence performance. Film and sheet manufacturers can recommend product combinations or variations that may provide significant performance advantages to the user.

Table 2. General and Thermal Properties of Film and Sheet...

Available as both film and sheet unless otherwise noted. All materials are available in PDA grades except for CTA, PVP, and PL EX = extrusion CL = calendering REG = regeneration CAST = casting BO = biaxial orientation. 

Polyethylene. Polyethylene remains the largest volume film and sheet raw material. It is available in a wide range of types, with variations in copolymers, homopolymers, molecular weight, and other factors contributing to a long Hst of resins. Resins are designed specifically for end use, and in addition blends of the various types may be used by processors to optimize properties, processibiUty, and economics. Almost two-thirds of the volume of all polyethylene resins are used in film or sheet appHcations (see Olefin polymers). 

Polystyrene. Polystyrene (PS) film and sheet has the third largest production volume, behind only the polyethylenes and poly(vinyl chloride). 

The processes used commercially for the manufacture of film and sheeting materials are generaUy similar in basic concept, but variations in equipment or process conditions are used to optimize output for each type of film or sheeting material. The nature of the polymer to be used, its formulation with plasticizers (qv), fillers (qv), flow modifiers, stabilizers, and other modifiers, as weU as its molecular weight and distribution are aU critical to the... 

The basic methods for forming film or sheeting materials may be classified as follows melt extmsion, calendering, solution casting, and chemical regeneration. Of special note is the use of biaxial orientation as part of the critical manufacturing steps for many film and sheet products. 

Melt Extrusion. By far the most important method for producing film and sheeting materials reties on one or another of the various melt extmsion techniques (5). The main variations of melt extmsion are the slot (or flat) die-cast film process, the blown films process, and the flat die sheeting-stack process. These may be combined with one or more steps such as coextmsion wherein multilayer film or sheet is formed, biaxial orientation, and in-line coating (6). 

Solution Casting. The production of unsupported film and sheet by solution casting has generally passed from favor and is used only for special polymers not amenable to melt processes. The use of solvents was generally very hazardous because of their flammabiUty or toxic nature. The cost of recovery and disposal of solvents became prohibitive for many lower price film appHcations. The nature of the drying operations leads to problems with solvent migration and retention that are not problems with melt-processed polymers. 

Table 6 shows the sales estimates for principal film and sheet products for the year 1990 (14). Low density polyethylene films dominate the market in volume, followed by polystyrene and the vinyls. High density polyethylene, poly(ethylene terephthalate), and polypropylene are close in market share and complete the primary products. A number of specialty resins are used to produce 25,000—100,000 t of film or sheet, and then there are a large number of high priced, high performance materials that serve niche markets. The original clear film product, ceUophane, has faUen to about 25,000 t in the United States, with only one domestic producer. Table 7 Hsts some of the principal film and sheet material manufacturers in the United States.

Based on estimates of resin sales for film and sheet. Includes estimate of captive use for photographic film and pressure-sensitive tape. Table 7. U.S. Manufacturers or Distributors of Film and Sheet ... 

Packaging (qv) represents the largest market area for film and sheeting materials (15). It is a complex market with so many categories that it is difficult to get an accurate measure of end usage for specific materials (16). The stmcture of the marketplace which uses both monolayers of film, as well as converted composite stmctures and laminates, adds to the complexity. The ultimate user or packager may purchase raw film direcdy from a manufacturer, or use the same film laminated to one or more other films or substrates through a converter. The converter may buy film or extmde his own supply. Resin sales to film producers do not always correlate with their film sales, because of scrap and yield losses. 

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