Film casting of polycarbonate/multi-walled carbon nanotubes composites using ultrasound-assisted twin-screw extruder: experiment and simulation
-
Xiang Gao
Abstract
A one-step ultrasonic film casting process to manufacture nanocomposite films was developed, in which polycarbonate (PC) was mixed with multi-walled carbon nanotubes (CNT) and cast into films in one process. Numerical and experimental investigations of necking phenomenon were carried out for film casting of PC/CNT composites. Experimental results revealed that the necking along film line decreased with imposition of ultrasound and increasing CNT content, indicating that incorporation of CNT and imposition of ultrasound restrained the elongational flow behavior of melt, resulting in film of a larger width. Isothermal and nonisothermal numerical simulations of the process were performed. In isothermal simulations, the polymer melt was assumed to be maintained at the die temperature. In nonisothermal simulations, the temperature change along the film line was determined from heat transfer calculations with the WLF temperature-dependent viscosity. The simulated and experimental results on normalized film width, defined as a ratio of cast film width to die width, as a function of the distance from the die at various extension ratios were compared. The comparison indicated that changes in film width and thickness along the stretching direction in the nonisothermal process were in better agreement with experimental results than that in the isothermal process. Both experimental and simulated results showed a decrease of film width with take-up speed. Due to the presence of edge effect, the film width in experiment was lower than the simulated one. With incorporation of CNT, a better agreement between experimental and simulated results was obtained, due to a reduced edge effect in the film.
Acknowledgements
The authors would like to thank the NSF Division of Engineering under grant CMMI-1131342 for financial support and Sabic Innovative Plastics for providing polycarbonate resins.
-
Author contributions: All the authors have accepted responsibility for the entire content of this submitted manuscript and approved submission.
-
Research funding: NSF Division of Engineering grant CMMI-1131342.
-
Conflict of interest statement: The authors declare no conflicts of interest regarding this article.
References
Agassant, J.F., Avenas, P., Sergent, J.-P., and Carreau, P.J. (1991). Polymer processing: principles and modeling. Hanser Publishers, Munich.Suche in Google Scholar
Alaie, S.M. and Papanastasiou, T.C. (1991). Film casting of viscoelastic liquid. Polym. Eng. Sci. 31: 67–75, https://doi.org/10.1002/pen.760310203.Suche in Google Scholar
Aniunoh, K.K. and Harrisony, G.M. (2006). Experimental investigation of film formation: film casting. J. Plast. Film and Sheeting 22: 177–192. https://doi.org/10.1177/8756087906067323.Suche in Google Scholar
Bangarusampath, D.S., Ruckdäschel, H., Altstädt, V., Sandler, J.K.W., Garray, D., and Shaffer, M.S.P. (2009). Rheology and properties of melt-processed poly(ether ether ketone)/multi-wall carbon nanotube composites. Polymer 50: 5803–5811. https://doi.org/10.1016/j.polymer.2009.09.061.Suche in Google Scholar
Canning, K. and Co, A. (2000). Edge effects in film casting of molten polymers. J. Plast. Film and Sheeting 16: 188–203. https://doi.org/10.1177/875608700772677553.Suche in Google Scholar
Demay, K. and Agassant, J.F. (2021). The polymer film casting process – an overview. Int. Polym. Process. 36: 264–275. https://doi.org/10.1515/ipp-2020-4061.Suche in Google Scholar
d’Halewyu, S., Agassant, J.F., and Demay, Y. (1990). Numerical simulation of the cast film process. Polym. Eng. Sci. 30: 335–340. https://doi.org/10.1002/pen.760300604.Suche in Google Scholar
Dobroth, T. and Erwin, L. (1986). Causes of edge beads in cast films. Polym. Eng. Sci. 26: 462–467. https://doi.org/10.1002/pen.760260704.Suche in Google Scholar
Ekvall, R.A. and Low, J.R. (1964). Temperature dependence of tensile properties of polycarbonate films. J. Appl. Polym. Sci. 8: 1677–1689. https://doi.org/10.1002/app.1964.070080418.Suche in Google Scholar
Gao, X., Isayev, A.I., and Yi, C. (2016). Ultrasonic treatment of polycarbonate/carbon nanotubes composites. Polymer 84: 209–222. https://doi.org/10.1016/j.polymer.2015.12.051.Suche in Google Scholar
Gao, X., Isayev, A.I., Zhang, X., and J. Zhong, J. (2017). Influence of processing parameters during ultrasonic extrusion on the properties of polycarbonate/carbon nanotubes composites. Compos. Sci. Technol. 144: 125–138. https://doi.org/10.1016/j.compscitech.2017.03.019.Suche in Google Scholar
Handge, U.A. and Pötschke, P. (2007). Deformation and orientation during shear and elongation of a polycarbonate/carbon nanotubes composite in the melt. Rheol. Acta 46: 889. https://doi.org/10.1007/s00397-007-0179-6.Suche in Google Scholar
Hsieh, T.T., Tiu, C., Hsieh, K.H., and Simon, G.P. (2000). Characterization of thermotropic lquid crystalline polyester/polycarbonate blends: miscibility, rheology, and free volume behavior. J. Appl. Polym. Sci. 77: 2319–2330. https://doi.org/10.1002/1097-4628(20000906)77:10<2319::aid-app26>3.0.co;2-%23.10.1002/1097-4628(20000906)77:10<2319::AID-APP26>3.0.CO;2-#Suche in Google Scholar
Huang, K. and Isayev, A.I. (2017). Ultrasonic decrosslinking of peroxide-crosslinked HDPE in twin-screw extrusion: Part I. Process model and simulation. Polym. Eng. Sci. 57: 1035–1046. https://doi.org/10.1002/pen.24487.Suche in Google Scholar
Isayev, A.I. and Hosaki, T. (1991). Temperature in rubber moldings during injection molding cycle: simulation and experimentation. J. Elast. Plast. 23: 176–191. https://doi.org/10.1177/009524439102300303.Suche in Google Scholar
Isayev, A.I., Kumar, R., and Lewis, T.M. (2009). Ultrasound assisted twin screw extrusion of polymer nanocomposites containing carbon nanotubes. Polymer 50: 250–260. https://doi.org/10.1016/j.polymer.2008.10.052.Suche in Google Scholar
Kase, S. and Matsuo, T. (1965). Studies on melt spinning, I., “fundamental equations on the dynamics of melt spinning”. J. Polym. Sci., Part A: General Papers 3: 2541–2554. https://doi.org/10.1002/pol.1965.100030712.Suche in Google Scholar
Krause, B., Kunz, K., Kretzschmar, B., Kühnert, I., and Pötschke, P. (2020). Effect of filler synergy and cast film extrusion parameters on extrudability and direction-dependent conductivity of PVDF/carbon nanotube/carbon black composites. Polymers 12: 2992. https://doi.org/10.3390/polym12122992.Suche in Google Scholar
Lamberti, G., Titomanlio, G., and V. Brucato, V. (2001). Measurement and modelling of the film casting process 1. Width distribution along draw direction. Chem. Eng. Sci. 56: 5749–5761. https://doi.org/10.1016/s0009-2509(01)00286-x.Suche in Google Scholar
Niknezhad, S. and Isayev, A.I. (2013). Online ultrasonic film casting of LLDPE and LLDPE/clay nanocomposites. J. Appl. Polym. Sci. 129: 263–275. https://doi.org/10.1002/app.38725.Suche in Google Scholar
Satoh, N., Tomiyama, H., and Kajiwara, T. (2001). Viscoelastic simulation of film casting process for a polymer melt. Polym. Eng. Sci. 41: 1564–1579. https://doi.org/10.1002/pen.10855.Suche in Google Scholar
Song, C.H. and Isayev, A.I. (2000). Self-reinforced composites of various polyesters with PET/HBA based LCP. J. Polym. Eng. 20: 427–457. https://doi.org/10.1515/polyeng.2000.20.6.427.Suche in Google Scholar
Tang, W., Santare, M.H., and Advani, S.G. (2003). Melt processing and mechanical property characterization of multi-walled carbon nanotube/high density polyethylene (MWNT/HDPE) composite films. Carbon 41: 2779–2785. https://doi.org/10.1016/s0008-6223(03)00387-7.Suche in Google Scholar
Xiao, K.Q., Zhang, L.C., and Zarudi, I. (2007). Mechanical and rheological properties of carbon nanotube-reinforced polyethylene composites. Compos. Sci. Technol. 67: 177–182. https://doi.org/10.1016/j.compscitech.2006.07.027.Suche in Google Scholar
Yashin, V.V. and Isayev, A.I. (1999). A model for rubber degradation under ultrasonic treatment. Part I: acoustic cavitation in viscoelastic solid. Rubber Chem. Technol. 72: 741–757. https://doi.org/10.5254/1.3538831.Suche in Google Scholar
© 2022 Walter de Gruyter GmbH, Berlin/Boston
Artikel in diesem Heft
- Frontmatter
- Editorial
- Special issue for John Vlachopoulos
- Review Article
- Calendering of thermoplastics: models and computations
- Special Issue Contributions
- Film casting of polycarbonate/multi-walled carbon nanotubes composites using ultrasound-assisted twin-screw extruder: experiment and simulation
- Effect of mixing conditions and polymer particle size on the properties of polypropylene/graphite nanoplatelets micromoldings
- Extrusion foaming of linear and branched polypropylenes – input of the thermomechanical analysis of pressure drop in the die
- Improving the thickness distribution of parts with hybrid thermoforming
- Synergistic material extrusion 3D-printing using core–shell filaments containing polycarbonate-based material with different glass transition temperatures and viscosities
- TPU-based porous heterostructures by combined techniques
- Surfactant-free oil-in-oil emulsion-templating of polyimide aerogel foams
- Factors determining the flow erosion/part deformation of film insert molded thermoplastic products
- The extrusion of EPDM using an external gear pump: experiments and simulations
- News
- PPS News
Artikel in diesem Heft
- Frontmatter
- Editorial
- Special issue for John Vlachopoulos
- Review Article
- Calendering of thermoplastics: models and computations
- Special Issue Contributions
- Film casting of polycarbonate/multi-walled carbon nanotubes composites using ultrasound-assisted twin-screw extruder: experiment and simulation
- Effect of mixing conditions and polymer particle size on the properties of polypropylene/graphite nanoplatelets micromoldings
- Extrusion foaming of linear and branched polypropylenes – input of the thermomechanical analysis of pressure drop in the die
- Improving the thickness distribution of parts with hybrid thermoforming
- Synergistic material extrusion 3D-printing using core–shell filaments containing polycarbonate-based material with different glass transition temperatures and viscosities
- TPU-based porous heterostructures by combined techniques
- Surfactant-free oil-in-oil emulsion-templating of polyimide aerogel foams
- Factors determining the flow erosion/part deformation of film insert molded thermoplastic products
- The extrusion of EPDM using an external gear pump: experiments and simulations
- News
- PPS News
