Fabrication of high modulus films by solid state rolling

Abstract

AbstractSolid state rolling of semicrystalline polymers represents a high speed process for producing oriented, high modulus films, tapes, and sheets. The important process variables include roll temperature, thickness of initial sheet, roll speed, take‐up tension, roll diameter, and initial morphological state of the polymer. Roll temperature controls both the extent of maximum deformation and the rate of rolling. A minimum temperature exists for each polymer below which the orientation process is sharply limited. This condition is similar to the limitation present in the hydrostatic extrusion process, in which the alpha crystallization temperature limits the orientation process. Roll speeds as high as 20 m/min have been realized. It is apparent that film thickness and thickness reduction ratio have a strong effect on the ultimate rolling rate. The process, as currently practiced, is adiabatic, and therefore, heat transfer limited. The take‐up tension influences the extant of orientation in the amorphous phse of of the polymer. This in turn affects its thermal and chemical stability. The effect of roll diameter is to limit the extent of thickness reduction by causing roll‐film slippage when the roll dianmeter to thickness reduction ratio is below some as yet undetermined value. The initial morphological state of the polymer affects the amount of crystalline deformation possible, the surface texture of the rolled film, and the tear resistant of the oriented film.