Optical properties of highly transparent polypropylene cast films: Influence of material structure, additives, and processing conditions

Polypropylene homopolymers and ethylene/propylene-random-copolymers formulated with and without anti-blocking additives were extruded to cast films with an industrial scale extruder equipped with a soft box, a specific air knife that expels a higher volume of air at lower velocity. The films were analyzed as to their optical properties haze and clarity. A comprehensive topographical characterization was performed using atomic force microscopy (AFM) and confocal microscopy. To obtain morphological information on a nanometer scale AFM phase imaging, micro-thermal analysis and small angle X-ray scattering (SAXS) were done. A significant effect of additives and processing conditions on the film topography and the optical properties was revealed. The films without anti-blocking and antacid aids showed the best optical properties and lowest vertical roughness fluctuations. In contrast, the addition of anti-blocking and antacid aids reduced the optical properties associated with an increase in surface roughness. While for films without anti-blocking aids an enhanced soft box condition resulted in lower vertical fluctuations of roughness and better optical properties, the behavior was in reverse for films with anti-blocking aid. By means of SAXS crystalline lamellae with a thickness of about 2.5 nm were detected. High-resolution phase imaging AFM yielded thicker crystal lamellae on the film surface.