UNCLASSIFIED

AD_295 734

ARMED SERVICES TECHNICAL INFORMATION AGENCYARLINGTON HALL STATIONARLINGTON 12, VIRGINIA

UNCLASSIFIED

NOTICE: When government or other drawings, speci-fications or other data are used for any purposeother than in connection with a definitely relatedgovernment procurement operation, the U. S.Government thereby incurs no responsibility, nor anyobligation whatsoever; and the fact that the Govern-ment may have formulated, furnished, or in any waysupplied the said drawings, specifications, or otherdata is not to be regarded by implication or other-wise as in any manner licensing the holder or anyother person or corporation, or conveying anly rightsor permission to manufacture, use or sell anypatented invention that may in any way be relatedthereto.

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TECHNICAL REPORT

TRANSPARENT SKIN AND BLISTER PACKAGING

13y 19. •J63

R. L. Murrens .

TiSlA U,

Department of the Army Project No. 593-32-007

Ordnance Management Structure Code No. 5010.11.84200.51

Report No. 62-3600 Copy No._ _ _

IEL 1-9-100-2 Date 31 October 1962

DISTRIBUTED BY THE THIS REPORT MAY BE DESTROYED WHENOFFICE OF TECHNICAL SERVICES NO LONGER REQUIRED FOR REFERENCEU. S. DEPARTMENT OF COMMFRCEWASHINGTON 25, D. C.

The findings in this report are not to be construed

as -n official Department of the Army position.

"tupies Available at Office of recnnica! Services $ .75

Report No. 62-3600

Copy No.

TRANSPARENT SKIN AND BLISTER PACKAGING

By

R. L. Murrens

Approved by:

A. C. HANSONLaboratory Director

31 October 1962

Department of the Army ProjectNo. 593-32-007Ordnance Management Structure CodeNo. 5010.11.84200.51

Rock Island ArsenalRock Island, Illinois

ASTIA Availability Notice:

Qualified requesters may obtaincopies of this report from ASTIA.

ABSTRACT

Transparent skin and blister packages enclosing steelpanels and various small items were fabricated by vacuumforming and electronic sealing equipment and submitted tovarious laboratory accelerated tests for evaluation. The re-sults of these tests indicated that a polyester/polyethylenelaminate as a skin packaging material would provide level Aprotection. Both vinyl and cellulose acetate butyrate haveexcellent clarity and qualities for fabrication with automa-tic vacuum forming and electronic sealing equipment. Thesematerials have limited use. When formed into blisters andsubjected to low temperature and high humidity tests, theblisters exhibited embrittlement, cracking, and swelling.

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CONCLUSIONS AMD RMCOMMENDATIONS

Based on the results of tests conducted, it is concludedthat the transparent polyester/polyethylene laminate is sat-isfactory for use as skin packaging material and as a unitbarrier for level A protection. It is recommended that thismaterial be considered for applications in Ordnance packaging.

Vinyl and cellulose acetate butyrate are satisfactory asblister packaging materials and are recommended for appli-cations in Ordnance packaging, except for packs that will en-counter temperature lower than -35F.

It was concluded that plain uncoated polyethylene inthicknesses ranging from 0.010 inch to 0.030 inch exhibitedfabrication difficulties, especially in sealing. Polyethyleneis not recommended for applications in Ordnance packagingwhere skin and blister methods are used.

0ii 62-3600

TRANBPARINT SKIN AND BLISTER PACKAGING

CONTENTS

Page No.

Object 1

Introduction 1

General Procedure 3

Procedure and Re�u1ts 3

A Blister Pack - Test A 3

(1) Method of Test 3

(2) Results 4

B Blister Pack - Test B 6

(1) Method of Test 6

(2) Results 8

C Blister Pack -Test C 8

(1) Method of Test 8

(2) Results 14

D Blister Pack-Test D 14

(1) Method of Preparation 14

(2) Results 16

I Skin Pack-Test 1 16

(1) Method of Test 16

(2) Results 2.8

Discussion

Appendix 20.

Distribution 210

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TRANSPARENT SKIN-AND BLISTER PACKAGING

OBJECT

To evaluate transparent plastic films utilizing blisterand skin packaging techniques as a means of providing adequateprotection and ready identification for Ordnance items.

INTRODUCTION

In order to insure that military items in storage are inready-for-issue condition, it in necessary to conduct periodicinspections. When opaque unit barriers are used, depackagingand repackaging are necessary with each inspection, and thecost of the original package may be multiplied many times.If transparent thermoplastic materials are used as unitbarrier materials, the expense of periodic inspections willbe less as the condition of the items can be observed throughthe barrier. In addition to this "see-through inspection"factor, many other advantages are possible, as thermoplasticmaterials are adaptable to blister and skin packaging tech-niques.

It was decided to evaluate blister and skin packs inlaboratory accelerated tests to determine the protectionafforded by various transparent barriers and their durabilityafter being heated and stretched under pressure. As a startingpoint, a literature search was conducted and plastic barrierswere chosen which appeared to have the qualities needed for alevel A military package. A vacuum forming machine, an elec-tronic sealer and a bar heat sealer were purchased.

After a preliminary testing period, in which the variousbarriers were fabricated into packs with the equipment, thefollowing materials were chosen which appeared to give thebest performance and show the most promise for militarypurposes: (1) cellulose acetate butyrate, (2) polyethylene,(3) polyvinyl chloride, (4) polyester, (5) polyester/poly-ethylene.

Historically, the forming of sheet plastics under heatand pressure had its beginnings in the late thirties, and im-portant progress followed with techniques developed during theSecond World War for forming contour maps. Then during thefifties, thermoforming began its rapid climb into the fieldof packaging,

*he term "skin pack' refers to a package unit where a4$ermoplastie film has been formed directly over the item to

* 62-3600

LI)

@4

a backing board by heat and pressure. The term "blister"refers to a simple curved or angular shape of thermoplasticnot conforming to the shape of the item. The "contour" packdiffers from the "blister" in that the "contour" conforms tothe shape of the item. Blister and contour packs use semi-rigid thermoplastic, while skin packs use flexible film.

Vacuum forming equipment ranges in complexity fromsimple laboratory type hand pump models selling for one hun-dred dollars or less to regular production line models inthe range of one to several thousand dollars and then up tospecialized automatic push button type machines that sell forten thousand dollars and higher. Among recent developmentsare machines that do a complete forming and packaging job.Machines of this type are now employed in the packaging ofthread, spark plugs and razor blades. Vacuum machines areavailable in sheet and roll fed models.

In skin packaging operations the items to be skinpackaged are placed on a mounting board. The items arepositioned uniformily by means of a template, and the board"is placed on a screen support above the vacuum area of themachine. Thermoplastic film is placed securely in a movableframe suspended above the items to be packaged. Heaters arethen brought over the film. As the film becomes soft andpliable from the heat, it is lowered and a vacuum beneaththe board causes atmospheric pressure to force the film intoa skin tight engagement with the items and the board. Thepaperboard portion of the package is usually coated with aheat responsive material which seals it to the hot film.when the inner surface of the film is polyethylene, thepolyethylene'will adhere to most paperboard surfaces withoutthe need of special board coatings.

Ilectronic sealing is accomplished by sending a highfrequency current through two or more layers of thermoplasticmaterial placed between two (unheated) sealing electrodes. ordies. These shaped bars cat perform both the sealing andthe cutting function. T~e dies are usually mounted in apneumatic or hydraulic press to provide pressure for fusingthe material. The seal is accomplished when high frequencyelectric current heats and liquefies the material and thepressure exerted brings a thorough fusion* JWesure is usedto assure intimate contact of the interfaces and time is em-ployed to bripg the interface to sealing temperature which ist~e welding temperature or temperature at which the interface

i disappears. These three variables all have upper limits.Temperature is limited by damage to the material. Pressureis limited I4y thinning of the seats and time is limited be*cause of production objectives*

2 62-3600

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GENERAL PROCEDURE

Tests were conducted to evaluate the performance of skinand blister packs in various environments. All environmentswere produced by laboratory equipment. The following environ-ments were used for test purposes: (a) high temperature 165 F,(b) low temperature -65 F, (c) a combination of high tempera-ture and high humidity (120 F at 98 to 100% R.H.), (d) a com-bination of high temperature 165 F (oven) and fresh waterimmersion at room temperature, (e) a combination of low temp-erature -65 F and high humidity of 95% R.H. at 95-100 F, and(f) cyclic exposure test A of MIL-P-116*. These test environ-ments would determine the effectiveness of heat seals to remainintact and the ability of skin and blister barriers to protectsteel panels after undergoing distortion caused by heat andpressure in the vacuum former. Items used in the skin andblister test packs consisted of steel panels and miscellaneouselectronic parts including vacuum tubes.

The steel panels acted as corrosion indicators and theelectronic parts represented basic examples of irregular formsfor blister packs. Packs containing vacuum tubes were notplaced in environmental tests. Each steel panel (2" wide by3" long by 1/8" thick) weighed approximately 3 ounces and wasprepared with one sandblasted surface and one polished surface.All panels were from the same type of steel (1020). Prior topackaging, the panels were cleaned and dried in accordancewith the cleanliness criteria specified in NIL-P-116, butgenerally only normal precautions were observed. Sheet androll type stock was used immediately after it was cut or re-moved from a roll or stack of sheets. The inclusion of VCIin the packs was accomplished in accordance with paragraph 3.6of IIL-I-8574. One tenth gram and one gram quantities wereused. For assurance of closure, all packs were leak testedaccording to MIL-P-116 paragraph 4.4.3 prior to the start ofthe test.

Steel panels were also placed in pouches fabricated fr~m*• KIL-B-131 and MIL-B-121 materiaTs for purposes of comparisoff.

No rough handling or storage aging tests were conducted.

PROCEDUREAND RESULTS

A Blister Pack -. Test A

(1) Method of Test

Packs 1 through 4 consisted of opaque Sarriers. It wasnecessary to cut open the pack in order to inspect the panel.

*See Appendix

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One pack was scheduled for opening and inspection after every7th day. The test exposure of packs 1, 2, 3 and 4 was com-pleted after six weeks. Packs 5 through 10 consisted oftransparent barriers, and the condition of the steel panelsinside was evaluated by observation through the barrier afterevery 7th day, The transparent packs were not opened untilafter the completion of the test period of 182 days.

Each pack contained 6 (2"1 by 3" by 1/8") steel panelssealed separately and spaced equally from each other. Theheat seals were 1/2"1 wide and were made on the heated bartype sealer. Embossed aluminum tags were also sealed insidethe packs for identification purposes.

The MIL-B-121 and MIL-B-131 materials were sealed at atemperature of 425 F, 2 seconds dwell and a pressure of 30 psi.The vinyl was sealed at 300 F, 2 seconds dwell and a pressureof 26 psi. The barrier material, its thickness and preser-vation method used for each transparent pack, ate listed inTable I, column 2. Vapor corrosion inhibitor in 1/10thgram quantities was placed inside half of the packs just priorto making the final seal. All packs were leak tested prioPto the start of the test.

(2).,Results

SA summary of the results is preseateil Ip Sable I. 4panel enclosed in MIL-G,;2l male•lal without lIe showed lightrust after one week of exposure. No rust wts bbsegve& onany panel enclosed in MILmG-1I2 wt "hI until after the jthweek of exposure when the 6th panel was examined. $

No rust was observe 8 on atqfs eaclosed in IL-B-5.1material without Iex until after the 5th week when the 6thpanel displayed rust* The panels enq.osed iM M"-131 withVCI showed the same results wheS tie Gfh panel after the 5thweek showed rust.

Panels enolosed im polyester mitjerial 40Qa0 inch thick)without VCI showed incipient rust afeV 7 days of exposure.

a A special tape* for sealing po3yestei film was used to sealthis material to itself. J4t the final inspection after 182days, the total rust accumulation on each panel averagelfrom 10 to 25%. Rust was not observed on panels enclosed inpolyester (0*005 inch thick) with VCI until after 119 daysof exposure. The fina% inspection after g82 days revealedtwo panels nearly rupt free, each showing a rust accumulation

*See Code Sheet, No. 7

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of less than 1%. The other 4 panels were disqualified forthe final inspection as they became mixed when seam sepa-rations occurred after 172 days.

All 6 panels enclosed in vinyl (0.010 inch thick) with-out VCI showed rust after 7 days in exposure. At the finalinspection after 182 days, each panel showed approximately10-25% rust accumulation.

Two panels enclosed in vinyl (0.010 inch thick) withVCI showed 1-5% rust on each of their Surfaces after thefirst 7 days of exposure. There was no further noticeableincrease in rust on these panels during the remainder ofthe test period. At the final inspection after 182 days,the rust accumulation on each of the 6 panels ranged fromone-half of 1% to 10%. The polished sides of the panelsexhibited slightly less rust than the sandblasted side.Panels 1 and 2 each showed less than 1% on the polishedsides. The sandblasted sides of each exhibited less than 2%scattered light rust dots. The polished sides of panels 3and 6 both showed singlto rust dots representing less thanonevhalf of 1% rust accumulation. The sandblasted side ofpanel 3 showed 5% while the sandblasted side of panel 6showed less than 5%. The polished sides of panels 4 and 5showed 5% rust coverage. The sandblasted side of panel 4showed 5-10% coverage. Panel 5 displayed a heavy rust spotrepresenting less than 2% rust accumulation on its sand-blagted sidee

-4 • •B Eiisteg Pack - Test

(1) Method of Test

All packs were fabricated from f0.020 inch thick) vinyl.0 Q See Figure 1. The contours were formed by heat and vacuum

on a vacuum forming machine. Plaster-ofsParis molds were* used. The items were enclosed by sealing a flat sheet of* (0.020 inch thick) vinyl to the flanges of thercontour with

e the electronic sealer.

The plaster-of-Parts molds were prepared by positioningthe item on its broadest base and masking the item downward

* with tapet The masked item was then placed in a vacuumformer and thin gauge plastic was drawn over it to form acavity. The plaster-of-Paris mixture was then poured intothe cavity forming a mold.

Zhe items selected were not over five pounds in weight.No preservatives were used. Moisture indicator cards wereplaced in each pack.

6 62-3600

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The .020 inch thick vinyl was sealed electronically usinga filament voltage of 7, a dwell time of 8-9 seconds, an am-perage of 20, and a die pressure of 75 psi. See Figure 2.The sealed packs were leak tested prior to their placement intest.

(2) Results

A summary of results is presented in Table II.

After 30 consecutive days of humidity and low tempera-ture cycle exposure test, good clarity was maintained by eachpack and no seam trouble developed. Swelling occurred inapproximately 50% of the packs and stress cracks occurred ontwo blisters. See Figure 3. Cracks developed along theinside edge of the seam in 2 packs.. Small areas of conden-sation were observed, both on the inner side of the barriersand on the enclosed items of all packs remaining in:the testfor 30 days. All ferrous parts of items remaining in testfor 30 days displayed light to medium rust. The chemical inthe indicator cards was leached in all packs completing 30days. Although corrosion data were obtained, the test was notconducted for this purpose, but to evaluate the performanceof blisters after maximum draw in the vacuum former. Resultsshowed that electronic heat seals were satisfactory, but needfor preservation inside blisters and need for forming materialsresistant to swelling and cracking was apparent.

C Blister Pack - Test C t

(1) Method of Test

Ten sheets of specimens were prepared. Each sheet con-sisted of 9 cavities. Each cavity contained one ball bearing.See Figure 4. Seven of the 9 bearings were coated with pre-servatives. Two iremalnod. unpreserved as controls. Thebarrier materials and preservatives are listed in Table III.The location of the preservative in relation to the positionof the cavity on the sheet was randomized on each of the 10sheets.

The cavities were formed in the vacuum former. The poly-ethylene was sealed with the heated bar sealer, and the ace-tate sheets were sealed with the electronic sealer.

The following test procedure was used in sequence:

a. Static low temperature at -35F for 48 consecutivehours.

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13 62-3600

b. Fresh water immersion at room temperature for 48consecutive hours. After withdrawal - room tempera-ture for 72 consecutive hours.

c. Cyclic exposure, MIL-P-116 test A. After withdrawal -room temperature for 72 consecutive hours.

d. Humidity cabinet static storage at 10OF and 95-100%R.H. for 720 consecutive hours.

(2) Results

The results of the cyclic exposure tests are summarizedand presented in Table III. The results are based upon ob-servations conducted immediately after the test and onceagain after the blisters were opened.

The controls (no preservative) performed as expected.Nearly all bearings with no preservation exhibited corrosion.The G-65 emulsifiable rust preventive performed in similarmanner. MIL-C-16173, Grade 3 provided corrosion free pro-tection only to bearings sealed inside cellulose acetate andcellulose acetate butyrate blisters. MIL-G-3278 and MIL-G-10924 provided corrosion protection to approximately 60% ofthe items regardless of barrier material. MIL-L-6085 andVCI coated kraft provided corrosion protection to all bearingsduring the test. MIL-L-644, NIL-G-3278, and MIL-G-10924provided corrosion protection only to bearings sealed insidecellulose acetate blisters.

D Blister Pack - Test D

(1) Method of Preparation

A multipackenclosing glass vacuum tubes, was fabricatedfrom (0.015 inch thick) vinyl. See Figure 5. The multipackbarrier consisted of a molded sheet and a plain flat sheet.In forming the pack, the molded sheet and the flat sheetwere sealed on the high frequency sealing press.

In preparation for vacuum forming, each vacuum tube wasenclosed by a small sheet of (0.005 inch thick) polyestermaterial wrapped around the tube to form a heat resistantsleeve. The items were next placed upon a plain sheet of(0.010 inch thick) Bristol board whose length and widthdimensions were trimmed to fit the vacuum former. The Bristolboard sheet was marked into rectangular areas of equal spacingbetween items to facilitate proper forming and sealing. The

14 62-3600

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FIGURE 5 15 62-3600

items were fixed to positions on the board with rubber adhe-sive to prevent any shifting which might occur during theforming cycle.

During the actual forming a (0.020 inch thick) vinylsheet was heated to forming temperature and lowered over theitems where vacuum was applied. This caused a conformanceand partial enclosure of each item leaving only a smallnarrow opening directly below each item.

The contoured sheet with the partially enclosed itemswas then sealed to a flat sheet on the electronic sealer.Seals were made parallel with the long axis of the vacuumtubes. Eight seals were completed with 12-15 seconds dwellat 60 pounds pressure and 17 amps. Thirty-five items werethen isolated or unitized by 14 seals. The multipack wasfabricated from 2 vinyl sheets of similar thickness(0.020 inch), however, a backing sheet of (0.010 inch thick)vinyl has been found to seal successfully to the contouredsheet of (0.015 inch thick) vinyl. Attempts to seal a flatsheet of (0.010 inch thick) vinyl to (0.010 inch thick) vinylmolded sheet were not successful. Thin areas were producedin the vacuum drawn sheet which caused arcing during theelectronic sealing operation.

Attempts to use filter paper as a base upon which theitems could be placed for vacuum draw were not successful.Although the nature of the paper allowed for maximum drawand distribution of force, a pebble grain impression wasformed on the flat surfaces of the formed sheet. Theserough surfaces would not produce as effective a heat sealas a flat smooth surface.

(2) Results

No environmental tests were conducted.

Z Skin Pack - Test Z

(1) Method of Test

All packs were made from polyester/polyethylene lami-nates of 3 thicknesses: 0.003 inch, 0.0025 inch, and 0.001inch. Steel panels were skin packed to (0.010 inch thick)Bristol board on the vacuum forming machine. The laminatedboard containing the steel panels was trimmed so that a 1/2inch border of plastic film remained around the edge of the

Q board. See Figure 6. The border strip was then sealed toitself on three sides after the board was folded. The closure

16 62-3600

4

FIGURE 6 177230

of the unfolded type pack was made by sealing the same ma-terial to the border of all 4 sides. The seals were accom-plished on a heated bar sealer at 2 seconds dwell, 220F. and40 pounds pressure. The packs were then placed in a cyclicexposure test: oven temperature at 165F. for 8 hours andfresh water immersion at ambient temperature for 16 hours.On weekends the test packs remained in the fresh water im-mersion tank.

(2) Results

The polyester/polyethylene laminate adhered firmly touncoated and unperforated (0.010 inch thick) Bristol board.The polyethylene component fused effectively to itself whenthe board was sandwiched between the 2 film laminates. How-ever, due to heat resistance, the polyester component doesnot permit a complete vacuum draw or full conformance to thecontours of the part.

TABLE IV

OVEN AND WATER IMMERSION TIST* - SKIN PACKS

Barrier MaterialTest Thickness and

No. Pres. Method Results

1 * Polyester/polyethylene No rust on any panel after0.003, no VCI, not folded '22 weeks.

2 Polyester/polyethylene No rust on any panel after0.003, with VCI, 22 weeks.not folded

3 Polyester/polyethylene No rust on any panel after0.003, with VCI, folded 22 weeks.

4 Polyester/polyethylene No rust on any panel after0.0025, with VCI, 22 weeks.not folded

5 Polyester/polyethylene Light rust area appeared on0.003, no VCI, folded one panel after 17th week,

no significant increase since.

6 Polyester/polyethylene Very light rust evenly dis-0.001, no VCI, folded persed over three of four

panels appeared after 22 wks.

*Oven temperature at 165F (for 8 hrs.) alternated byimmersion in fresh water (for 16 hr..) at ambienttemperature for 22 weeks.

18 62-3600

DISCUSSION

The vacuum tube multipack (Figure 5) incorporates 'oome ofthe important features of a transparent package: Transp arencyfor ease in identification and inventory, and immobility ofitem to minimize shock and vibration. The design of themultipack provides for equal spacing and distribution ofweight. Stacking and packing procedures are facilitated. Oneitem may be removed from the multipack sheet as a completeunit without contaminating other items or the item removed.The detached pack can remain intact until it is necessary toremove the item. Also, changes in sizes of intermediate con-tainers and shipping containers may be accomplished withoutchanging the design of the unit pack.

To simulate conditions that would be normal in practice,no exceptional precautions were taken to control the atmos-phere of the processing area during packaging. Panel surfaceswere exposed to a nondust free atmosphere for a brief timeduring processing.

In slectronicsealings the sealing jaws or electrodesremain unheated and the fusion of the thermoplastic takesplace when an electric field penetrates the material in-stantly and thoroughly. Jaw pressure can be held to a mini-mum, thus preventing thinning and extrusion. It is possibleto recognize incompletely fused areas during sealing, asthese areas will show up as slightly opaque when compared tothe clearer transparency of an adequate seal.

319 62-3600

APPENDIX

Cyclic Exposure, Test A - EIL-P-116

Overnight at 120 F. to 130 F.

Two hours of water spray at 50 F. to 60 F.

Two hours at -10 F. to 0 F.

Two hours of water spray at 120 F. to 130 F.

Two hours of water spray at 50 P. to 60 F.

Overnight at 35 F. to 50 F.

Four hours at 120 F. to 130 F.

Two hours of water spray at 50 F. to 60 F.

Two hours at 35 F. to 50 F.

Overnight at 120 F. to 130 F.

Two hours of water spray at 50 F. to 60 F.

Two hours at -10 P. to 0 F.

Three hours at 35 F. to 50 F.

Overnight at 120 F. to 130 F.

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