Cast Film Extrusion

Abstract

Abstract Cast film extrusion is a widely used technique to produce polymer films for packaging or coating applications. The final width of the film may be smaller than the initial die width (necking phenomenon) and therefore is the final film thickness larger than what one could expect. Moreover it is heterogeneous (in terms of showing a larger thickness along the borders, also called dog bone defect). Above a critical draw ratio between the chill roll and the die both width and thickness fluctuations are observed (Draw Resonance Instability). All these phenomena limit the productivity of the process. This paper provides an overview of the processing and material parameters governing the development of these geometrical defects and instabilities. Numerical models capturing the main experimental features are proposed, allowing to investigate process modifications in order to limit the development of these defects.