Investigating the thickness of patterned polyethylene layers by changing the line speed and temperature in the embossing machine

Patterned polyethylene films are mandatory products in the rubber tire industry. They are used as protective lining to prevent contamination of the rubber. This pattern geometry (2D and 3D) prevents the rubber from sticking to each other. The film is desired to be homogeneous, precise in thickness, and have sufficient mechanical strength. The speed and the temperature of the pattern-forming machine are among the factors that determine this relationship between the thickness of the film and its mechanical properties for sustainable quality production. In this study, the effect of the speed and the temperature of the pattern machine on the pattern thickness during the creation of the pyramid-shaped pattern applied on a 100 ± 5 µm thick polyethylene film were examined. Four different machine speeds (24, 26, 28, and 30 m/min) and three different temperatures (100, 110, and 120 °C) were studied as variables. The impact of parameters on film thicknesses and tensile properties was assessed. Film thickness varied from ~ 375 to ~ 340 µm at higher machine speed, strength-at-break values decreased from 28 to 22 MPa, and elongation values dropped from 575 to 437% with the increment in speed. On the other hand, at higher temperatures, thickness rose from ~ 360 to ~ 390 µm, and elongation values reduced from 440 to 410%. Within the scope of the experimental studies, it was observed that the film thickness changes and the mechanical properties can be controlled by changing the line speed or process temperature.