Beruflich Dokumente
Kultur Dokumente
Polymers Division
National Institute of Standards and Technology
Gaithersburg, MD 20899-8542
An optical sensor based on fiber optics has been developed to measure fluores-
cence anisotropy and temperature during processing of biaxially stretched polypro-
pylene films. The sensor, containing optical fibers, polarizing elements and lenses,
was mounted above the polypropylene film as it was processed in a tenter frame
oven stretching machine. Fluorescence observations were made using the fluores-
cent dye, bis (di-tert butylphenyl) perylenedicarboximide (BTBP), which was doped
into the resin at very low concentrations. To monitor biaxial stretching, fluorescence
anisotropy measurements were carried out with light polarized in the machine and
the transverse directions corresponding to the directions of biaxial stretching. Fluo-
rescence based temperature measurements were obtained from the ratio of fluores-
cence intensities at 544 nm and 577 nm. A matrix of experiments involving three
levels of stretch ratio in both the machine and transverse directions was under-
taken. We observed significant differences between anisotropy in the machine and
transverse directions that we attributed to the sequential stretching operation, i.e.,
the film was stretched in the machine direction first, followed by stretching in the
transverse direction, and to film temperature and strain rate for each stretching
operation. The result was uniformly higher anisotropies in the machine direction.
Film temperature obtained from fluorescence corresponded to oven thermocouple
measurements within 2°C. Polym. Eng. Sci. 44:805–813, 2004.
© 2004 Society of Plastics Engineers.
POLYMER ENGINEERING AND SCIENCE, APRIL 2004, Vol. 44, No. 4 805
Anthony J. Bur and Steven C. Roth
ratio and stretch temperature, after which they exam- The sensor combines two process monitoring con-
ined the state of HDPE film by various off-line tech- cepts, temperature and anisotropy, that we have devel-
niques including X-ray, atomic force microscopy (AFM), oped during the past several years using fluorescence
transmission electron microscopy, and differential techniques (1315). The measurement relies on the
scanning calorimetry, and refractive index observa- presence of a fluorescent dye that is mixed with the
tions. Their examination focused on the change in resin at low concentrations, less than 105 mass frac-
crystalline morphology from spherulitic lamellae into tion of dye in the resin. The dye used for this work is bis
lamellar stacks that resulted from MD stretch at tem- (di-tert butylphenyl) perylenedicarboximide (BTBP), a
peratures near the melting temperature. In another dye that possesses large molecular geometrical anisot-
study, Nie and co-workers used AFM after BOPP pro- ropy. BTBP is called a band definition dye and belongs
cessing to examine surface properties, but a detailed to a class of dyes whose spectra show marked temper-
examination of the biaxial stretching process was not ature dependence (14). The large geometrical anisotropy
carried out (2). enhances its orientation in extensional flows. Its size
Laboratory methods to characterize molecular ori- precludes inclusion in the crystalline structure of poly-
entation of the film product, such as X-ray diffraction, propylene (PP). The molecular structure of BTBP is
AFM, and birefringence, are usually carried out in post- shown in Fig. 1, where the double-headed arrow is the
processing tests, and many off-line experimental stud- direction of the absorption dipole.
ies of biaxial orientation and microstructure in blown Fluorescence anisotropy measurements yield infor-
film and uniaxial orientation of crystalline polymers mation about the orientation of the absorption dipole
have been published (310). But there have been very moment of a fluorescent dye that has been excited
few approaches to microstructure studies using on-line with polarized light. The technique has been used to
techniques. An on-line measurement of birefringence measure molecular orientation in polymer melts and
was developed by Cakmak and co-workers and was in solid polymer films and fibers (1522). Orientation
used to monitor uniaxial stretching of polyethylene information is obtained from the polarization of the
naphthalate (11, 12). The technique revealed gross ori- emitted fluorescent light. For this application, the di-
entation as well as subtle changes and the evolution rection of the incident light is polarized alternately in
of new microstructure during annealing. A method for the machine direction (MD) and the transverse direc-
on-line continuous monitoring of molecular orientation tion (TD). We measure two anisotropies, rM and rT , cor-
is desirable because it can yield a database record of responding to excitation light polarized in the machine
the process, can be utilized immediately to adjust ma- and transverse directions:
chine parameters to make a desired product, and can IMM IMT ITT ITM
be used as a sentry to detect quality problems. In this rM rT (1)
IMM 2IMT ITT 2ITM
paper, we report the development and implementation
of an on-line, real-time sensor based on fluorescence where IMM and IMT are, respectively, the intensities of
spectroscopy to monitor both orientation and temper- fluorescent light polarized in the machine and trans-
ature of biaxially stretched polypropylene. While X-ray verse directions, produced by incident light polarized
and birefringence measurements exclusively reflect or in the machine direction, and ITT and ITM are, re-
are dominated by crystalline orientation, a fluorescence spectively, the intensities of fluorescent light polarized
anisotropy measurement of a fluorescent dye that has in the transverse and machine directions, produced
been added to the resin should primarily reflect amor- by incident light polarized in the transverse direction.
phous orientation, which has a more profound effect on Equation 1 expresses anisotropy as the difference be-
the marginal improvement or variation of film proper- tween intensities of mutually perpendicular polariza-
ties. tions of fluorescence divided by the approximate total
Fig. 1. The molecular structure of BTBP. The arrow is in the direction of the absorption dipole.
806 POLYMER ENGINEERING AND SCIENCE, APRIL 2004, Vol. 44, No. 4
Real-Time Monitoring
fluorescence intensity. Anisotropy r is a dimensionless over the length of the stretch zone. After MD and TD
quantity, theoretically limited to the range 0.5 to 1 stretching, the film was pulled through the annealing
and independent of the amount of dye. section of the oven set at 160°C where the anisotropy
Several authors have developed molecular models sensor was positioned. The MD and TD mechanical
that yield a relationship between r and absorption di- stretch ratios, s M and s T , were varied systematically to
pole orientation factors (17, 19, 21, 23, 24). These the- study the relationship between fluorescence anisotropy
oretical models are not employed in this study. Instead, and process parameters. rMD and rTD were measured
we take the approach that an empirical application of at all nine combinations of s M 4, 5, 6 and s T 6.6,
Eq 1 can yield qualitative and operational principles 8, 10 by holding s T constant while increasing s M in
regarding the biaxial film stretching process. If tem- steps to 4, 5 and 6. For each set of eighteen measure-
perature is held constant during an experiment, it is ments, the anisotropy sensor was moved along a posi-
possible to obtain a set of internally consistent data that tioning rail to three positions on the transverse axis,
reveal the effects of orientation. The data presented designated as West, Central and East, where the Cen-
below were obtained at constant temperature and pres- tral position was at the center of the film and East
sure so that the observed changes in anisotropy are and West were separated from it by 0.46 m. The full set
due to molecular orientation as expressed in the geo- of measurements yielded 54 data points. Since wind-
metrical orientation factors of the dye’s absorption di- ing speed and tenter stretch zone length were kept
pole moment. constant, changes in stretch ratio were accompanied
According Eq 1, the measurement of rM and rT in- by proportionate changes in strain rate.
volves the separate observations of pairs of fluores- Fluorescence Anisotropy Sensor (15). A sketch of
cence intensities, IMM and IMT , and ITT and ITM . For on- the sensor is shown in Fig. 2. The stainless steel sen-
line, real-time observations, each pair of intensities sor head has a rectangular cross section (38.1 mm by
must be measured simultaneously. The sensor that 50.8 mm) in order to maintain a recognizable direction
we employ here is designed to detect the pair intensi- of light polarization. The solid stainless steel block
ties simultaneously, and we will demonstrate its use (106 mm length) has been machined with channels and
for monitoring rM and rT during biaxial stretching of compartments that receive the optical fibers and opti-
polypropylene film in a tenter oven at approximately cal components, and it is blackened in order to reduce
160°C. We present the results from real-time process internal light reflections. Focusing and polarizing op-
monitoring carried out at different machine set-points. tics, needed to excite a fluorescent dye with polarized
The second function of the sensor, to monitor tem- light and to analyze the polarization of the generated
perature, is based on the shape of the fluorescence fluorescence, are placed in internal compartments that
spectrum and its dependence on temperature. The secure their position when the sensor is in operation.
technique has been described in detail in previous Excitation light at 488 nm, produced by an air-cooled
publications (13, 14). Briefly, the ratio of intensities at argon ion laser from Coherent, is transmitted to the
two wavelengths vs. temperature is the basis for ob- sensor and specimen via one or the other of the op-
taining the temperature of the resin in the dye’s molec- tical fibers positioned in the sensor channels. Light
ular neighborhood. The calibration procedure is dis- polarized in the machine direction is produced when
cussed in the next section. light travels along the center channel path and di-
EXPERIMENTAL PROCEDURE 2 rectly through the calcite crystal. Light polarized in the
transverse direction is produced by light that travels
Our experiments were conducted on a Marshall and the side channel path. The fiber-optic bundles in both
Williams tenter frame biaxial stretching machine at channels of the sensor head are bifurcated into two
the pilot plant facility of ExxonMobil Chemical Co. in branches, with one branch transmitting excitation light
Macedon, N.Y. In the tenter frame stretching opera- and the other collecting and carrying fluorescence to
tion, polypropylene resin is first extruded into a strip the detector. Both fiber cables have identical design
or sheet that is cooled below its crystallization temper- consisting of nineteen 200 m core fused silica fibers,
ature. After traversing a series of rollers as it crystal- eighteen of which carry fluorescence to the detector,
lizes and anneals, the strip is brought to the entrance and the other single fiber transmits the excitation light.
of the oven, where it is grabbed at both edges by mov- One central fiber for excitation light is surrounded by
ing clamps of the tenter frame and pulled into the oven
eighteen fibers for fluorescence collection. A single ex-
(1). The entry zones of the tenter frame oven were
citation fiber was deemed necessary because a uniform
maintained at 132°C. For our experiments, stretching
focus of light onto the PP film is best produced by a sin-
was carried out sequentially, first MD and followed by
gle fiber rather than several fibers. The total length of
TD stretching. Typical conditions for MD stretching
the fiber cable is 4 m with bifurcated branches having
were 132°C at 13 s1 strain rate, and for TD stretch-
0.5 m length. The fiber bundle is protected over the
ing they were 158°C at 0.6 s1, declining to 0.075 s1
length of the cable with stainless steel strip wound
flexible sheathing. Fiber cables of our custom design
2Identificationof a commercial product is made only to facilitate experimental were purchased from Schott-Fostec. More detail about
reproducibility and to describe adequately the experimental procedure. In no
case does it imply endorsement by NIST or imply that it is necessarily the best
polarization optics, light paths, and sensor construc-
product for the experiment. tion is available in Reference 15.
POLYMER ENGINEERING AND SCIENCE, APRIL 2004, Vol. 44, No. 4 807
Anthony J. Bur and Steven C. Roth
A block diagram of the full setup is shown in Fig. 3. times in a row, after which the TD sensor position was
The entire optics assembly was placed in a light-tight changed. The r data reported below are therefore based
enclosure in order to eliminate stray light from enter- on averages of 100 to 200 intensity measurements. rM
ing the photomultiplier tubes (PMTs). A beamsplitter and rT are not measured simultaneously, but this is of
divides the excitation light at 488 nm from the laser little consequence because we observed the steady
into two beams directed to optical fibers in the center state condition of the process over an extended period
and side channels of the sensor. Shutters open to di- of time, 15 min or more at each machine set-point.
rect the laser beam to these channels one at a time, Detection of fluorescence is done with photomultiplier
and alternately open and close at 10 s intervals. The tubes and Stanford Research SR400 photon counter.
generated fluorescence, which has transmitted through At the entrance to each PMT, light passes through a
the calcite crystal polarizer and is collected by optical dispersion prism that deflects 488 nm excitation light
fibers in the center and side channels, corresponds to away from the PMT, but fluorescence with 500 nm
light polarized in the machine and transverse direc- passes through wide-band filters transmitting over
tions respectively. Each intensity measurement was a the most intense part of the fluorescence spectrum,
photon count integrated over 1 s. Ten such measure- 510 nm to 590 nm.
ments of IMM and IMT were taken simultaneously; then In order to account for the difference between fluo-
the shutters were switched to repeat the procedure rescent light transmission through the side and center
for ITT and ITM . This sequence was repeated 10 to 20 channels, calibration of the sensor is necessary. This
808 POLYMER ENGINEERING AND SCIENCE, APRIL 2004, Vol. 44, No. 4
Real-Time Monitoring
involves obtaining a value for g, the ratio of transmis- from the calibration curve of Fig. 4. The fluorescence
sions in the two branches. The calibration consists of temperature was calibrated by slowly raising the oven
measuring rM and rT of an oriented film at room tem- temperature from about 70°C to about 150°C and then
perature, then rotating the film 90° and repeating the lowering it back to 70°C with a stationary piece of
measurements to obtain r M and r T . At 0° the expres- BOPP film. The ratio I 544 /I 577 and air temperature
sions for r containing the g-factor are T of the BOPP film were measured simultaneously
where T was obtained from a thermocouple touching
IMM gIMT gITT ITM the film near the focused excitation light beam. The in-
rM rT (2)
IMM 2gIMT gITT 2ITM creasing and decreasing temperature data are very well
fitted by distinct straight lines, which differ slightly (3%)
At 90° we have in slope. The difference can be entirely explained by the
IMM gIMT gITT ITM air-film thermal lag. Taking the averages of slopes and
r M r T (3) intercepts produces an accurate calibration equation.
IMM 2gIMT gITT 2ITM
The sensor was located in the annealing section of
The equivalence between the 0° and 90° measurements the oven 15 mm above the film surface and immedi-
dictates that ately after MD and TD stretching had occurred. Thus,
we were not observing the dynamics of the stretching
r M rT r T rM (4)
operation, but the post stretching and annealed condi-
These two equations provide two independent values tion of the film. The sensor could be placed in any TD
of g, which should be close to each other if experimen- position by means of a traversing mechanism. Meas-
tal error is low. The g-factors determined following this urements were taken at the tenter centerline and near
procedure were found to be g 0.318 and g 0.337. the West and East film edges as depicted in Fig. 5.
This discrepancy is small compared to the precision The TD dimension of the film, which depended on the
required here. The root mean square relative error is stretch ratio, was approximately 1.5 m. By means of
minimized for g 0.327. the traversing rail, the sensor could be raised and
The third channel in the sensor contains collection shuttled to a background measurement station where
optical fibers that transmit fluorescence to the PMT anisotropy readings were taken at process temperature
detectors for the temperature measurements. This is against a non-fluorescent, non-reflective black sur-
shown as the dashed line in the sensor body of Fig. 2. face. A background measurement series preceded each
These fibers collect fluorescence and direct it to a beam- West-Center-East fluorescence measurement sequence.
splitter that separates the fluorescence into two beams Background intensities I bMM , I bMT , I bTT and I bTM were
that are filtered respectively at the 544 nm and 577 obtained and subtracted from the corresponding in-
nm with narrow bandpass filters positioned at the en- tensities measured later on oriented film.
trance to the detecting PMTs. Photons from the PMTs The biaxially stretched film material is made from
are counted using another SR400 photon counter, and polypropylene doped with BTBP dye. The polypropyl-
the ratio I 544 /I 577 is used to calculate the temperature ene was Fina 3371. BTBP was purchased from Aldrich
Fig. 4. Temperature versus the ratio of fluorescence intensity at 544 nm and 577 nm. I544/I577.
POLYMER ENGINEERING AND SCIENCE, APRIL 2004, Vol. 44, No. 4 809
Anthony J. Bur and Steven C. Roth
810 POLYMER ENGINEERING AND SCIENCE, APRIL 2004, Vol. 44, No. 4
Real-Time Monitoring
Fig. 7. Bar charts of rM and rT at the East, Center, and West The statistical significance of both coefficients is very
positions. high, and potential second or higher-order terms are
Fig. 8. Anisotropy rM as a function of MD stretch ratio at various TD stretch ratios. Data are from Center position.
POLYMER ENGINEERING AND SCIENCE, APRIL 2004, Vol. 44, No. 4 811
Anthony J. Bur and Steven C. Roth
Fig. 9. Anisotropy rT as a function of TD stretch ratio at various MD stretch ratios. Data are from Center position.
not significant. The standard uncertainty of fit is 0.08. important conclusion from this figure is the absence
Whether this moderate lack of fit is due to experimen- of correlation between rM and rT . Hence, these two ori-
tal uncertainty or to other factors controlling orienta- entation indices are independent. This is not surpris-
tion is unknown. However, crystallinity plays no role ing in a biaxially orientated film, which requires two
because the dye is present in the amorphous phase orientation factors for complete characterization.
only. Multiple regression using the full set of rM data In Fig. 10, also note the systematic difference in rT
from East, Center and West positions yields the fol- between the East, Center and West positions. In fact,
lowing: this difference is comparable in magnitude to some of
the effects in Fig. 8. In other words, film of varying
rM 0.582 0.0925s M 0.0431s T 1R 2 0.602 (6)
effective stretch ratio was produced at different TD
A similar attempt to fit the rT data using multiple re- positions. Yet the film made throughout these experi-
gressions yielded statistically insignificant relation- ments had less than 3% gauge variation and no visual
ships for all sensor positions. The value of rT is not in- defects. This exemplifies the hidden non-uniformities
fluenced by machine direction stretching, and, as this method can help detect.
seen in Fig. 7, transverse stretching beyond 6.6 had
little effect on rT . The data of Fig. 9 show that rT does CONCLUSIONS
not monotonically increase with s T or s M . Part of the The satisfactory operation of the fluorescence tem-
difficulty may be due to the smaller range of rT com- perature and anisotropy sensor was demonstrated dur-
pared to rM . This can be seen more clearly in Fig. 10, ing biaxial stretching of polypropylene film in a tenter
which includes data from all TD positions. Another oven. The two anisotropy measures rT and rM were
Fig. 10. rT versus rM for all stretch ratio experiments and all three positions.
812 POLYMER ENGINEERING AND SCIENCE, APRIL 2004, Vol. 44, No. 4
Real-Time Monitoring
consistent with each other as shown by the g-fac- 5. T. C. Ma and C. D. Han, J. Appl. Polym. Sci., 35, 1725
tor calibration. The r measurements for the biaxially (1988).
6. Y. M. Kim, C. H. Kim, J. K. Park, C. W. Lee, and T. I. Min,
stretched polypropylene film were also statistically in-
J. Appl. Polym. Sci., 63, 289 (1997).
dependent of each other. The standard uncertainties 7. A. Perterlin, Colloid Polym. Sci., 253, 809 (1975).
of the anisotropy measurements were low. At steady 8. I. L. Hay and A. Keller, J. Mater. Sci., 4, 908 (1969).
state, web temperature measured by fluorescence 9. R. J. Samuels, Structured Polymer Properties, John Wiley,
agreed well with adjacent air temperature measured New York (1974).
10. P. B. Bowden and R. J. Young, J. Mater. Sci., 9, 2034
by thermocouple. (1974).
In a designed experiment carried out with the in- 11. J. Galay and M. Cakmak, J. Polym. Sci. Polym. Phys.,
strument in a tenter oven, rM followed intuitive expec- 39, 1107 (2001).
tations in its dependence on the MD and TD stretch 12. J. Galay and M. Cakmak, J. Polym. Sci. Polym. Phys.,
ratios. The behavior of rT could not be explained easily, 39, 1147 (2001).
13. A. J. Bur, M. G. Vangel, and S. C. Roth, Polym. Eng.
but the low strain rates and relatively high tempera- Sci., 41, 1380 (2001).
ture of the TD stretch are most likely the basis for the 14. A. J. Bur, M. G. Vangel, and S. C. Roth, Appl. Spec., 56,
rT observations. Significant TD positional variation in 174 (2002).
rT was detected on the particular tenter used. 15. A. J. Bur, S. C. Roth, and C. L. Thomas, Rev. Sci. Instr.,
71, 1516 (2000).
ACKNOWLEDGMENTS 16. Y. Nishio, H. Suzuki, and K. Sato, Polymer, 35, 1452
1461 (1994).
The authors wish to acknowledge a very fruitful col- 17. A. J. Bur, C. L. Thomas, S. C. Roth, and F. W. Wang,
laboration with Moris Amon of ExxonMobil Chemical Macromol., 25, 3503 (1992).
Co., who assisted us while installing the anisotropy 18. B. Erman and L. Monnerie, Polymer, 28, 727 (1987).
19. J. H. Nobbs, D. I. Bower, I. M. Ward, and D. Patterson,
sensor and running the experiments on the ExxonMobil
Polymer, 15, 287 (1974).
tenter frame oven process line. 20. L. L. Chappoy, K. Rasmussen, and D. B. DuPre, Macro-
mol., 20, 680 (1979).
REFERENCES 21. P. Lappersonne, P. Sergot, L. Monnerie, and G. LeBour-
1. V. Ratta, G. L. Wilkes, and T. K. Su, Polymer, 42, 9059 vellec, Polymer, 30, 1558 (1989).
(2001). 22. S. Maruse, M. Hirami, Y. Nishioi, and M. Yamamoto,
2. H. Y. Nie, M. J. Walzak, and N. S. McIntyre, Polymer, 41, Polymer, 38, 4577 (1997).
2213 (2000). 23. A. Szabo, J. Chem. Phys., 72, 4620 (1980).
3. H. Y. Zhou and G. L. Wilkes, J. Mater. Sci., 33, 287 (1998). 24. C. Zannoni, Mol. Phys., 38, 1813 (1979).
4. R. J. Pazur and R. E. Prud’homme, Macromol., 29, 119 25. A. Hald, Statistical Theory With Engineering Applications,
(1996). John Wiley, New York (1952).
POLYMER ENGINEERING AND SCIENCE, APRIL 2004, Vol. 44, No. 4 813