Poly film production

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.

The series of ten different segmented poly(ester-urethane)s obtained was characterized by SEC (molecular weight, polydispersity), DMA (thermo-mechanical properties), DSC (thermal properties) and Instron (mechanical properties). Before the mechanical testing could be performed, it was necessary to establish procedures for film production. 

Polv(ethylene terephthalate). Poly(ethylene terephthalate) film is a widely used industrial product. However, only a small fraction of the total film production is used in electrical applications (see also section on polymers for electronic applications). 

Weathering is critical with film products, such as the 250 [xm thick LDPE film coverings of agricultural poly-tunnels. It is accepted that the film will only last a couple of seasons, but the lightweight aluminium tube support structure has a low capital cost, in comparison to the complex and strong structure needed to support glass panes in greenhouses. 

PEDOTiPSS was first introduced in an industrial product as a roll-to-roll deposited antistatic layer on biaxially oriented poly(ethylene terephthalate) (PET) during photographic film production in order to avoid unwanted, stray electrostatic discharges within the photoactive layers during film processing. The use of PEDOTiPSS as the conductive ingredient in the antistatic layer proved particularly advantageous because... 

Acrylics. Acetone is converted via the intermediate acetone cyanohydrin to the monomer methyl methacrylate (MMA) [80-62-6]. The MMA is polymerized to poly(methyl methacrylate) (PMMA) to make the familiar clear acryUc sheet. PMMA is also used in mol ding and extmsion powders. Hydrolysis of acetone cyanohydrin gives methacrylic acid (MAA), a monomer which goes direcdy into acryUc latexes, carboxylated styrene—butadiene polymers, or ethylene—MAA ionomers. As part of the methacrylic stmcture, acetone is found in the following major end use products acryUc sheet mol ding resins, impact modifiers and processing aids, acryUc film, ABS and polyester resin modifiers, surface coatings, acryUc lacquers, emulsion polymers, petroleum chemicals, and various copolymers (see METHACRYLIC ACID AND DERIVATIVES METHACRYLIC POLYMERS). 

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

A viscous solution of poly(amic acid) can be processed into films, fibers, and coatings, and the final product undergoes thermal cyclo dehydration. 

Optics. Good optical properties and low thermal resistance make poly(methyl methacrylate) polymers well suited for use as plastic optical fibers. The manufacturing methods and optical properties of the fibers have been reviewed (124) (see Fiber optics). Methods for the preparation of Fresnel lenses and a Fresnel lens film have been reported (125,126). Compositions and methods for the industrial production of cast plastic eyeglass lenses are available (127). 

Attempts have been made to use cold-set adhesives in the cormgating operation, such as poly(vinyl acetate) and modified, precooked starch formulations, but these have not achieved any appreciable degree of commercial acceptance (20). The use of a polyethylene film appHed to the inside surface of the linerboard facing, which serves as a hot-melt cormgator adhesive, has achieved some commercial usage. However, its use is limited to the small, specialty product niche of fast-food hamburger cartons (see Olefin polymers, polyethylene). 

The adhesives (qv) used to form tube seams and bag bottoms include unborated dextrin, borated dextrin, casein, latex—casein, latex, poly(vinyl acetate), vinyl acetate copolymers, and hot-melt materials (10,27). Dextrin and casein adhesives are more commonly used in the production of grocery sacks vinyl acetate-type adhesives are commonly used in ah paper multiwah bags. The hot-melt adhesives are typicahy used to tack the phes of the multiwah bag together and to form the seam and bottom joints when polymer film phes or coated paper phes are used in bag constmction. 

Phthahc anhydride (1) is the commercial form of phthaUc acid (2). The worldwide production capacity for the anhydride was ca 3.5 x 10 metric tons ia 1993, and it was used ia the manufacture of plasticizers (qv), unsaturated polyesters, and alkyd resins (qv) (see Polyesters, unsaturated). Sales of terephthahc acid (3) and its dimethyl ester are by far the largest of any of the benzenepolycarboxyhc acids 14.3 x 10 t were produced in 1993. This is 80% of the total toimage of ah. commercial forms of the benzenepolycarboxyhc acids. Terephthahc acid is used almost exclusively for the manufacture of poly(ethylene terephthalate), which then is formed into textiles, films, containers, and molded articles. Isophthahc acid (4) and trimehitic anhydride (5) are commercial products, but their worldwide production capacities are an order of magnitude smaller than for terephthahc acid and its dimethyl ester. Isophthahc acid is used primarily in the production of unsaturated polyesters and as a comonomer in saturated polyesters. Trimehitic anhydride is used mainly to make esters for high performance poly(vinyl chloride) plasticizers. Trimesic acid (6), pyromehitic dianhydride (7), and hernimehitic acid (8) have specialized commercial apphcations. The rest of the benzenepolycarboxyhc acids are not available commercially. 

Thermoplastic Processing. Poly(ethylene oxide) resins can be thermoplasticaHy formed into soHd products, eg, films, tapes, plugs, retainers, and fillers (qv). Through the use of plasticizers (qv), poly(ethylene oxide) can be extmded, molded, and calendered on conventional thermoplastic... 

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