Solvent Cast Technology - A Versatile Tool
Solvent Cast Technology - A Versatile Tool
Solvent Cast Technology - A Versatile Tool
DOI 10.1007/b107336
Published online: 3 June 2005
Springer-Verlag 2005
Ulrich Siemann
U. Siemann
LOFO High Tech Film GmbH,
Weidstr. 2, 79576 Weil am Rhein,
Germany
e-mail: [email protected]
Tel.: +49-7621-703-114
Fax: +49-7621-703-313
Introduction
From the end of the 19th century, the development of a
process for manufacturing thin plastic lms was tightly
linked to the emerging industry for movies and photographic lms. 5 mil (125 micron) lm was produced using
a discontinuous device with a caster moving over 200 feet
long glass plates at Eastman KODAK [1]. Soon, rst
patents were issued to cast celluloid lms on a moving
surface by the Celluloid Company in the United States
and patented in 1896 [2]. For economic reasons, Eastman
KODAK developed a continuous casting process
parallel to the Celluloid Company, resulting in a patent
infringement. KODAK switched over from the discontinuous to the continuous casting process about 5 years
later. At that time, photographic lm base was produced
from cellulose nitrate and campher as a plasticizer from
Ether, Esters
Acetone, Methanol
Methylene Chloride, Alcohols
Polycarbonates
Polyethersulfon
Polyetherimide
Polyvinylidene uoride
PVC (Polyvinyl chloride)
Methylene Chloride
Methylene Chloride
Methylene Chloride
Acetone
Tetrahydrofuran
Methyl-ethylketon
Polyimides
Dimethylformamide
Polyvinylalcohol
Methyl Cellulose
Starch derivatives
Gelatine
Water, Methanol
Water
Water
Water, Methanol
c1
c2
e
a = caster, die, hopper
b = steel belt
c1 = support drum (driven)
c2 = rear support drum (steered)
d = belt channel
e = drying air
f = film take-off
e
f
e
A
= manifold of coathanger die
B1/B2 = preland sections
d
a
b
d
e
f
3
2
1
2
3
4
5
6
50
solven conc. of film (%)
45
T (film) > Tg
40
T1
35
30
25
T2
T (film) < Tg
20
15
10
5
0
0.01
0.1
10
100
1000
1 = film
2 = pin tenter
3 = casting die
4 = support drum
5 = stripping roll
6 = hot air
7 = drying chamber
8 = grooved roll
Roller cabinet
* 8 h- TWA limits
[mg/m3]
** STEL
[mg/m3]
Max. wastewater
concentration [mg/l]
Acetone
1200
4800
150
30
260
1040
150
10
36
360
1440
20
0,1
230
Methanol
Methylene
chloride
>50 g/m3
1100 g/m3
150 g/m3
>25 g/m3
>20 g/m3
>10 g/m3
3 ... 10 g/m3
0.23 g/m3
10
De-sorption at 120 C
Adsorption at 30 C
40
adsorption process
heating
30
20
cooling
10
de-sorption process
0
0
0.05
0.1
0.15
0.2
0.25
0.3
11
Use of energy
Process
Technical experience
Feed concentration
Concentration in cleaned air
Corrosion
Probability of incidents
Purity of recovered solvent
Absorption (Liquid)
12
4
3
5
1 = dope mixer
2 = holding tank
3 = de-aeration device
4 = condenser
5 = solvent recovery, schematic
On the other hand, the performance and, more specifically, the high quality of solvent cast lms cannot be
achieved using other processes. This will described in the
next chapter.
LCD applications
LC Cell Side
Fig. 15 Cross-section of a LCD polarizer
13
These membranes are used in normal-sized and miniature loudspeakers, e.g. for mobile phones. Typical raw
materials are polycarbonate and polyarylate [21].
To achieve a controlled pore structure, another
inherent advantage of solvent casting is used [22]:
14
Conclusion
The oldest technology for the production of thin polymer
lms is nowadays used for niche products with high
quality requirements such as photographical lm base,
exible printed circuits, high-temperature resistive lms,
loudspeaker membranes etc. In recent years, mainly new
optical applications needed new amorphous lms with
highest clarity and specic optical birefringence properties. In most cases, these amorphous lms are not easily
accessible by Rulands structural investigation methods,
because the absence of microdomains or crystallinity is
one of the assumptions to provide good solubility in
organic solvents and in particular a perfect glass-like
appearance after the lm formation process. The future
of solvent cast technology will be closely linked to the
need of optical lms by the emerging liquid crystal
display industry or other new optical applications which
require polymer lms with outstanding properties.
Acknowledgement I am most honoured to have the opportunity to
proer my profound gratitude to Professor Ruland, who was able,
during my thesis work, to explicate the mysteries of the reciprocal
room ... even to a chemist.
References
1. Collins D (1990) The story of Kodak.
HN Abrams Inc, New York
2. Steven, Leerts (1896) USP 573928
3. Couzens EG (1968) A short history of
the lm casting process and its products. Bexford Ltd, Essex
4. Adelstein PZ et al (1972) Manufacture
and physical properties of lm. Paper
and plates. 127 , Neblettes handbook
of photography and reprography
5. Sata H, Murayama M, Shimamoto S
(2004) Properties and application of
cellulose triacetate lm. p 323333,
Macromol. Symp. 208 (2004)
6. Lippert HG (1987) Polymers, lamination and coatings conference. 193
7. Durst F et al (1989) Coating, 434