PVC Products for the Production of Rigid Films - Vinnolit

ContentPVC GRADES FOR THE PRODUCTION OF RIGID FILMS ........................................................ 2PVC PRODUCTS FOR THE PRODUCTION OF SEMI-RIGID AND FLEXIBLE FILMS......... 3COPOLYMERS FOR IMPROVED THERMOFORMING PROPERTIES.................................... 4PROPERTIES AND APPLICATIONS OF EMULSION PVC.......................................................... 5GRAFTED COPOLYMERS AS IMPACT MODIFIER FOR FILMS ............................................. 6GRAFTED COPOLYMERS FOR FLEXIBLE FILMS WITH LITTLE OR NO MIGRATION.. 7PVC WITH HIGH MOLECULAR WEIGHT FOR ANTIBLOCKING, MATTING ANDTEXTURING.......................................................................................................................................... 8GENERAL INFORMATION................................................................................................................ 9® Registered Trademark of Vinnolit GmbH & Co. KG, Germany

Page 2/9PVC Products for the Production of Rigid FilmsExamples for rigid films:Packaging, credit cards, pharmablister, adhesive tapes etc.® Vinnolit grade K valueDIN 53726Viscosity no.(cm 3 /g) DIN 53726Co/GraftcomponentBulk density(g/l)DIN 53466Typical applicationsS-PVC(Suspension PVC)E-PVC(Emulsion PVC)S 3160 60 89 - 570 Standard grade for rigid filmsE 2059 59 86 - 500Blending component for rigid films promotesfaster fusion and supports antistatic propertiesE 2078 78 159 - 460 Special grade for Luvitherm processK 301 * * - 550 Antistatic agent for transparent, rigid filmsCopolymersS 3060/10S 3157/116057898010 % VAC11 % VAC620650Main or blending component for highly transparentrigid films to improve thermoformingperformanceVK 801K 707 E****50 % EVA50 % ACR570550Impact modifier for opaque or pigmented rigidfilms suitable for outdoor useGraftedCopolymersVK 710 * * 50 % ACR 650K 725 F * * 50 % ACR 500Impact modifier as described above with additionalrelease effectImpact modifier for articles with very low stresswhiteningand is suitable for exterior applicationsGrades forantiblocking,matting andK 240C 100 V**texturing K 221 * * - 590**--600630Antiblocking or matting agentTexturing agent, gives a sand-blasted or frostedeffect* cannot be determined exactly with common methods ® Registered Trademark of Vinnolit GmbH & Co. KG, GermanyVACEVAACRVinylacetateEthylen-vinylacetate-copolymerPolyacrylic rubber

Page 3/9PVC Products for the Production of Semi-Rigid and Flexible FilmsExamples for semi-rigid and flexible films:Roofing sheets, label films, insulating tapes, tarpaulins, artificial leather etc.® Vinnolit grade K valueDIN 53726Viscosity no.(cm 3 /g) DIN 53726GraftcomponentBulk density(g/l)DIN 53466Typical applicationsS 4170 70 124 - 480 Standard grade for flexible filmsS 4170 AOF 70 124 - 480 Antioxidantfree grade for flexible filmsS-PVC(Suspension PVC)E-PVC(Emulsion PVC)S 4080 80 168 - 450S 4099 99 300 - 450E 2169 69 120 - 410Grade for flexible films with improved mechanicalproperties and for thick calenderedfilmsSpecial grade for flexible films with improvedmechanical properties especially at high temperaturesAdditive for semi-rigid and flexible films forfaster fusion, E 2169 also supports antistaticpropertiesGraftedCopolymersVK 801K 707 E****50 % EVA50 % ACR570550Grades for flexible films with low or no migration.VK 801 is the standard type, K 707 Eshows enhanced resistance to chemicalsGrades forantiblocking,matting andtexturingC 100 V * * - 630 Antiblocking or matting agentK 221 * * - 590Texturing agent, gives a sand-blasted orfrosted effect* cannot be determined exactly with common methods ® Registered Trademark of Vinnolit GmbH & Co. KG, GermanyVACEVAACRVinylacetateEthylen-vinylacetate-copolymerPolyacrylic rubber

Page 4/9Copolymers for Improved Thermoforming Properties® Vinnolit S 3060/10® Vinnolit S 3157/11Calendered or extruded rigid films are usually producedwith S-PVC having K values between 57 and61.If improved performance for subsequent thermoforming,welding, glueing or printing is required,copolymers containing vinyl acetate (such asVinnolit S 3060/10 or S 3157/11) can be used.These products are random copolymers of vinylchloride and vinyl acetate and are produced bymeans of the suspension process. They generallyhave a vinyl acetate content of about 10 % andK values between 57 and 60.viscosity at 190 °C [Pa * s]100 1000 10000 100000S 3160S 3160 60 phr, S 3157/11 40 phrS 3060/1010 100 1000shear rate [1/s])Fig. 1: Melt viscosity of S-PVC, Copolymer anda blend of both products (log. scale)Compared with homopolymeric PVC, copolymerizedproducts show two superior properties, i.e.low melt viscosity (Fig. 1) and high melt elongation,especially at low processing temperatures (Fig. 2).A low melt viscosity improves the welding and laminatingproperties, and for good thermoformingproperties a high melt elongation is also important.These copolymers are therefore suitable asblending components to improve the followingproperties:• Large vacuum formed articles can be producedat relatively low temperatures, resultingin a shorter cycle time. Thus copolymersenhance the performance of film during subsequentprocessing to e.g. blister packaging• Films containing copolymers are easier tolaminate and weld. Copolymers also allowthe production of highly transparent filmswith excellent printability. Copolymers aretherefore essential for the manufacture ofcredit cards, identity cards etc.elongation at break [%]0 300 600S 3160S 3160 60 phr, S 3157/11 40 phrS 3060/1070 90 110 130 150temperature [°C]Fig. 2: Elongation at break measured on0,2 mm films (thermoelastic temperaturerange). The test films werebased on S-PVC (blue line), a blendof S-PVC and S 3157/11 (60:40, greenline), and S 3060/10 (red line).

Page 5/9Properties and Applications of Emulsion PVC® Vinnolit E 2059® Vinnolit E 2169® Vinnolit E 2078® Vinnolit K 301E-PVC for thermoplastic processing has severalmorphological characteristics which influence boththe processing behaviour as well as the finishedarticle. As a consequence of the emulsion polymerisationprocess, E-PVC consists essentially ofprimary particles (size usually 0.2-1.5 µ see Fig.3.) surrounded by a thin emulsifier layer. Theseprimary particles are sintered during the dryingprocess (drum or spray drying) into larger, freeflowing agglomerates, which constitute the actualpowder particles. These E-PVC grains are readilybroken down into their constituent primary particlesduring thermoplastic processing. Formulationscontaining E-PVC fuse rapidly and are soondispersed into a homogenous blend. For this reasonalso, E-PVC, aided by the emulsifier, facilitatesthe production of optically faultless films withfew flow lines and a low fish-eye count.10µmThe processing ease also permits S/E blendingwith E-PVC of a higher K value, a simple variantfor raising the mechanical properties of the film.Additional advantage: Additives, which are difficultto disperse, such as pigments and fillers, can beincorporated and homogenised much more easilyin formulations containing E-PVC.The emulsifiers contained in the E-PVC arehygroscopic. In addition to the effect as a processingaid, this characteristic enables E-PVC to beused for films with improved antistatic properties.E-PVC for thermoplastic processing is mainlyused as a blending component with S-PVC. Typicalproportions range between 5 and 40 %. In thecase of antistatic films, a minimum quantity ofE-PVC from 20 – 25 % is recommended; whenused as a processing aid 5 – 10 % often is sufficient.1 µmFig. 3: REM microphotographs of cross sectionsof standard S-PVC (upper picture)and E-PVC (below). The looselyagglomerated primary particles differfrom the solid structure of S-PVC andwill disperse more easilyVinnolit GmbH & Co. KG offers a range ofproducts which differ in K value and emulsifiercontent, thus making it possible to select the idealproduct for any application:E 2059 is the standard processing aid in rigidfilms.On account of the higher K value, E 2169 is thepreferred blending component in semi-rigid orflexible film formulations.K 301 is a special E-PVC grade containing additionalantistatic agent. With K 301 enhanced antistaticproperties can be achieved in rigid films withvery little effect on transparency.The Luvitherm process is a special procedure forthe processing of E-PVC. In this process, E-PVCwith a high K value is processed to thin, usuallystretched, high quality rigid films such as adhesivetapes. E 2078 has proved itself to be excellent forthis purpose.

Page 6/9Grafted Copolymers as Impact Modifiers for Films® Vinnolit VK 710® Vinnolit VK 801® Vinnolit K 707 E® Vinnolit K 725 FModifiers are frequently used to increase impactstrength. An impact modifier is almost alwaysused in rigid films. This is especially the case forsemi-rigid and flexible films if embrittlement at lowtemperatures is to be avoided or if a combinationof impact resistance with simultaneous reductionin migration is required. Vinnolit GmbH & Co. KGoffers 3 impact strength modifiers for the film producingindustry. VK 710, K 725 F and K 707 E,both graft polymers consisting of 50 % acrylicester rubber (ACR) and 50 % PVC, and VK 801, agraft polymer consisting of 50 % ethylene-vinylacetate copolymer (EVA) and 50 % PVC. Theseproducts offer the following advantages:• The rubber particles are easily distributed andform discrete structures in the PVC matrix.This structure permits the production of impact-resistantfilms over a wide processingrange.• The rubber particles are grafted with PVC.This ensures an ideal adhesion to the PVCmatrix.• The modifiers are based on EVA - or ACR -rubber. This allows applications with excellentresistance to UV, weathering and ageing.• K 707 E is the standard grade for impactmodification. Its advantages are fast fusionand high surface quality of the finished article.• VK 801 has additional advantages regardingsmoke density, a property important for flameretardant films. It also causes a silk matt finishof the film surface.• In addition to improving the impact strength,VK 710 also functions as a release agent.• K 725 F is a special impact modifier for productswhere stress-whitening is an issue.Articles manufactured with K 725 F show verylow stress-whitening.• All products are free-flowing powders whichcan be supplied in bag, big bag or silo.penetration work [Nm/mm 2 ]30201000 4 8 12phr VK 71023°CFig. 4: Results of a dart test measured on rigidfilms based on S 3160 containing VK 710.Depending upon the type and quantity of the plasticizer,impact strength modifiers are commonly used inplasticized films in order to reduce the cold crack temperature.Table 1 for example, shows the characteristicphysical properties of two semi-rigid films havingthe same shore hardness with and without VK 801.When using VK 801, K 707 E, K 725 F or VK 710,plasticizer migration can also be reduced at the sametime.Table 1:Formulation:® Vinnolit S 4170® Vinnolit VK 801DINPBa/Zn- stabilizer0°C82-1827510152PropertyShore D (DIN 53505) 73 73Cold crack (DIN 53373) [°C] -5 -22

Page 7/9Grafted Copolymers for Flexible Films with little or noMigration® Vinnolit VK 801® Vinnolit K 707 EClassical flexible PVC, i.e. PVC with monomericplasticizers, is common because of its good processingproperties. Depending upon the plasticizer type,quantity and application, the phenomenon of plasticizermigration can play an important role in someapplications. Typical migration problems are embrittlementduring long-term stress, pigment blooming,sticky and dirty surfaces, low resistance to extractionor the softening of label adhesives. Thisproblem can be reduced with plasticizers of a highermolecular weight (e.g. polyester plasticizers). Migration-resistantmaterials can be achieved by alloyingPVC with flexible polymers (EVA, PEC, NBR etc.).However, this requires a more complex processingtechnique to achieve an adequate melt homogeneity.Vinnolit graft copolymers do not have the above mentioneddisadvantages. Being a polymeric substance,the flexible component (EVA or acrylic rubber) ismigration-resistant, and by grafting with PVC, anideal homogeneity is achieved. Although the proportionof rubber is 50 %, nevertheless they are freeflowingpowders and silo storage is possible.The individual products: VK 801 (50 % EVA, 50 %PVC) is the standard grade of this product group.K 707 E (50 % ACR, 50 % PVC) is preferred where ahigh resistance to chemicals is required.The Shore hardness is an important criterion in formulationsfor flexible sheets. VK 801 has an inherenthardness of approx. Shore A 82. Higher Shore Avalues are achieved by blending with PVC, but alsowith other polymers such as SAN, PMMA or ABS.Softer products are achieved by combination with, forexample, EVA, Et-VAC-CO terpolymer, PEC, NBR orTPU. The variety of alloy partners permits the productionof custom-made materials for special requirements,e.g. Shore hardness, resistance toweathering or ageing, as well as resistance to abrasion,chemicals or heat.Mixtures based on Vinnolit graft copolymers cangenerally be processed on typical equipment suitablefor the production of PVC films, and the formulationknow-how can also be transferred to this group ofmaterials. In contrast to conventional flexible PVC,these materials fuse rapidly and have a higher meltviscosity. The high viscosity allows production ofthicker films, such as roofing sheets, of up to 1,5 mmin one calender operation. Typical calendering temperaturesrange from 175 to 180 °C.Migration-resistant, flexible sheets or laminated fabricsare required, for example, for roofing sheets,special tarpaulins, automotive films, conveyor belts,protective clothing, container linings etc. As anexample, the property characteristics of a nonreinforcedroofing sheet based on K 707 E, whichwas calendered with a thickness of 1.2 mm in oneoperation, is shown in Table 2.Table 2Shore A 77Tensile strength (DIN 53455) [N/mm 2 ] 18Elongation at break (DIN 53455) [%] 300Tear strength (DIN 53515) [N/mm 2 ] 25Cold crack temp. (DIN 53372) [°C]

Page 8/9PVC with High Molecular Weight for Antiblocking, Matting and Texturing® Vinnolit K 240® Vinnolit C 100 V® Vinnolit K 221Definitions:Blocking refers to the tendency for contactinglayers of plastic materials to stick together.The effect is enhanced by smooth surfaces. Asa result high forces must be overcome whenreels of film or sheet are being unwound, and itis more difficult to remove individual cut sheetsfrom a stack.Matting can be equated with a reduction of thesurface gloss. To the eye the sheet remainssmooth.Texturing is a special surface effect that canalso be achieved by means of embossing withsand-blasted rollers. The surface appearsuniformly rough, and the irregularities can beobserved with the naked eye.Antiblocking, matting and texturing properties areachieved by the selective introduction of irregularitiesinto the sheet or film. These irregularities takethe form of particles, which, although they arefirmly embedded in the product, cause small elevationsat the surface (see Fig. 6). Even relativelysmall amounts of Vinnolit K 240, C 100 V orK 221 produce the desired effect. Whether thesurface will be non-blocking, matt or textured dependson the size and amount of added particles.Even very small additions will prevent the blockingof sheet. Thus, only 0.3 – 1 phr K 240 or C 100 Vresult in a sufficient number of bumps so that individuallayers are no longer in intimate contact witheach other (see Fig. 7). These “spacers” cannotbe recognised visually.Fig. 7: Two film layers with "spacers“ causedby K 240The same applies to matt films if the quantity ofK 240 or C 100 V is increased to 3 – 10 phr. Theincident light is scattered by the uneven surface,which then appears to be matt or even “dull”(Fig. 8).reflectometer value (60°)1005000 5 10 15 20 25phr C 100 VFig. 8: Matting effect of C 100 V in rigid film.The reflectometer value shows the decreasinggloss.Fig. 6: Surface elevations on a film surfacecaused by K 221Vinnolit K 240, C 100 V or K 221 are used in theformulations as an additive. The number and sizeof particles present in the sheet are decisive fornon-blocking, matt or textured sheet.The individual particles of K 221 are exceptionallystable. During the usual conditions of thermoplasticprocessing, these particles are neither shearednor swollen by plasticizers and keep their initialsize of approximately 35 – 40 µ. Correspondinglyhigh elevations appear on the sheet surface.These are seen not as matt but rather as a “sandblasted”,textured surface. 5 – 10 phr K 221 producea “frosted" effect in transparent film, whichnevertheless retains a high contact transparency(underlying pictures or handwriting).Vinnolit K 240, C 100 V and K 221 result in “formulationmatt” surfaces. In contrast to mechanicalembossing e.g. with sand-blasted rollers, the desiredsurface structure is retained during subsequentdeformations such as vacuum forming.

Page 9/9General InformationFurther information and recommendations forprocessing can be obtained from our technicalsupport staff and representatives.The data and recommendations contained in thisbrochure represent the current state of our knowledgeand serve as a guide only to our productsand their potential applications. Therefore, nowarranty of specific properties of the productsmentioned herein nor of their suitability or fitnessfor a particular purpose is implied.The information given in this brochure should bechecked by preliminary trials because of conditionsduring processing over which we have nocontrol, especially where other companies’ rawmaterials are also being used.Patent or other proprietary rights of third partiesmust be observed. The quality of our products iswarranted under the terms of our General Conditionsof Sale.® Registered Trademark of Vinnolit GmbH & Co.KG, GermanyIsmaning, July, 2011Vinnolit GmbH & Co. KGCarl-Zeiss-Ring 25D-85737 IsmaningGermanyTel. +49 89 961 03-0Fax +49 89 961 03-103