Melt drawing of ultra‐high molecular weight polyethylene: Comparison of Ziegler‐ and metallocene‐catalyzed reactor powders

The drawing behavior of the ultra‐high molecular weight polyethylene (UHMW‐PE) melts has been studied by comparing the stress/strain curves for two types of samples as polymerized using conventional Ziegler and newer metallocene catalyst systems. Two UHMW‐PE samples, having the same viscosity average molecular weight of 3.3 × 10⁶, but different molecular weight distribution, have been drawn from melt at special conditions. The sample films for drawing were prepared by compression molding of reactor powders at 180°C in the melt. Differences in the structural changes during drawing and resultant properties, ascribable to their broad or narrow molecular weight distribution, were estimated from tensile tests, SEM observations, X‐ray measurements and thermal analyses. The metallocene‐catalyzed sample having narrower molecular weight distribution, could be effectively drawn from the melt up to a maximum draw ratio (DR) of 20, significantly lower than that obtained for the Ziegler‐catalyzed sample, ∼ 50. The stress/strain curves on drawing were remarkably influenced by draw conditions, including draw temperature and rate. However, the most effective draw for both was achieved at 150°C and a strain rate of 5 min⁻¹, independent of sample molecular weight distribution. The efficiency of drawing, as evaluated by the resultant tensile properties as a function of DR, was higher for the metallocene‐catalyzed sample having narrower molecular weight distribution. Nevertheless, the maximum achieved tensile modulus and strength for the Ziegler sample, 50–55 and 0.90 GPa, respectively, were significantly higher than those for the metallocene sample, 20 and 0.65 GPa, respectively, reflecting the markedly higher drawability for the former than the latter. The stress/strain behavior indicated that the origin of differences during drawing from the melt could be attributed to the ease of chain relaxation for the lower molecular weight chains in the melt. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 1921–1930, 1999     

Novel characterization of the crystalline segment distribution and its effect on the crystallization of branched polyethylene by differential scanning calorimetry

Based on a thermal segregation treatment, a novel semiquantitative method for the characterization of the crystalline segment distribution in branched polyethylene copolymers was established by the results of differential scanning calorimetry being treated with the Gibbs–Thomson equation. The method was used to describe the segment distribution of Ziegler–Natta‐catalyzed linear low‐density polyethylene (Z–N LLDPE), metallocene‐catalyzed linear low‐density polyethylene (m‐LLDPE), and a commercial linear low‐density polyethylene with a wide molecular weight distribution. The isothermal crystallization kinetics of Z–N LLDPE and m‐LLDPE were studied to assess the effect of different segment distributions. According to their molecular characteristics, the crystallization behaviors were analyzed. They indicated that the different segment distributions of the two polymers resulted in different crystallization processes, including the nucleation and growth of crystals under various crystallization conditions. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 2107–2118, 2002     

Thermal properties and influence of orientation on crystalline morphologies in stereoblock polypropylene and related elastomers

Atomic force microscopy (AFM), small angle X‐ray scattering (SAXS), temperature modulated differential scanning calorimetry (TMDSC), variable heating rate DSC, an independent rapid heating rate method for melting points, and cyclic mechanical testing were used to study semicrystalline thermoplastic elastomeric polypropylenes (ELPPs) and related semicrystalline polyolefins including ethylene copolymers. Low crystallinity (ca., 9 and 15%) ELPP samples were studied by AFM in the nonoriented and melt‐oriented states. AFM images taken as a function of time after quenching of a melt‐drawn and highly nucleated film resolved details of secondary crystallization involving lateral growth on the ordered row‐nucleated structures. For nonoriented films, isothermal melt crystallization at high temperatures (110 °C) led to similar features for the two ELPPs. The dominant crystalline morphology studied by AFM consisted of small (several nm in width) granular crystallites organized into immature but large spherulites spanning tens of microns. A striking cross‐hatch morphology was detected in regions of the surface in 110 °C crystallized samples, which is contrasted with melt‐drawn films where row nucleated structures dominated the morphology in the film under no external stress. AFM was also used to monitor the morphological changes that occurred as the films were stretched at 25 °C. Break‐down of lamellae was observed, resulting in oriented narrow fibrils. Cyclic stress‐strain curves showed the expected result where lower crystallinity ELPPs had higher recoverable levels of set after both 100 and 500% elongation. TMDSC was used to resolve the broad melting and recrystallization regions in these low to medium crystallinity ELPP systems, and to contrast the results with ethylene copolymers. © 2010 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys, 2011     

A WAXD/SAXS/DSC study on the melting behavior of Ziegler–Natta and metallocene catalyzed isotactic polypropylene

A small- and wide-angle X-ray scattering study was performed on two metallocene catalyzed isotactic polypropylene (miPP) resins. The results were compared with two similar molecular weight Ziegler–Natta catalyzed isotactic polypropylene (zniPP) materials. Wide-angle X-ray diffraction (WAXD) results showed the existence of two crystalline structures in the metallocene samples, the α-monoclinic and γ-orthorhombic crystal structure, with increasing relative amounts of γ-orthorhombic phase as the lamellae thickness increased. Differential scanning calorimetry (DSC) scans exhibited a melting peak for each crystal structure. The metallocene resins had the same equilibrium melting temperature (186 ± 2 °C) as the high tacticity Ziegler–Natta (ZNHT) resin, whereas a second Ziegler–Natta resin had a lower equilibrium melting temperature (178 ± 2 °C). The equilibrium melting temperature for the γ-orthorhombic crystal structure in the metallocene resins was found to be 178 ± 4 °C. The results were explained by the distribution of defects within the miPP chains, generating higher fold surface free energies for the miPP resins. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 3050–3064, 1999     

Single-crystal-like orientation of ultrahigh-molecular-weight polyethylene by uniaxial stretching

Dried gel film of ultrahigh-molecular-weight polyethylene (UHMW PE) can be drawn to 370 times its original length at 135°C. Single-crystal mats and dried gel film of UHMW PE develop double orientation despite uniaxial stretching. This is unique for preferentially oriented UHMW PE systems. To elucidate the origin of this single-crystal-like orientation, precursors with different aspect ratios were prepared and drawn uniaxially. The degree of double orientation was measured by infrared spectroscopy. The origin of single-crystal-like orientation seems to reside in the necking region. The stacked lamellar structure is transformed into a fibrillar structure in a two-dimensional fashion. This condition is easily provided when UHMW PE single-crystal mat or dried gel film is drawn uniaxially. A draw ratio of 40 and aspect ratio of 40 are the optimal conditions to obtain a doubly oriented structure from UHMW PE single-crystal mat or gel film at 135°C.     

Drawing of ultrahigh molecular weight polyethylene fibers in the presence of supercritical carbon dioxide

The drawing behavior of ultrahigh molecular weight polyethylene fibers in supercritical carbon dioxide (scCO₂) is compared to that in air at different temperatures. The temperature substantially influences the drawing properties in air, whereas in scCO₂, a constant draw stress and tensile strength are observed. Differential scanning calorimetry shows an apparent development of a hexagonal phase along with a significant increase in the crystallinity of air‐drawn samples with increasing temperature. The existence of this phase is not confirmed by wide‐angle X‐ray scattering, which instead shows that air‐drawn samples crystallize in an internally constrained manner. In contrast, scCO₂ allows crystals to grow without constraints through a possible crystal–crystal transformation, increasing the processing temperature to 110 °C. © 2003 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 1375–1383, 2003     

Phase Development Mechanism during Drawing from Highly Entangled Polyethylene Melts

Summary: The phase development mechanism during drawing from a highly entangled melt of ultra‐high‐molecular‐weight polyethylene is analyzed by simultaneous measurements of in situ X‐ray diffraction using synchrotron radiation and stress/strain behavior. The stress/strain curve exhibits a plateau region at the initial stage of the draw, and no crystalline reflections appear on a series of in situ X‐ray diffraction patterns. However, as the sample draw proceeds above a critical strain, a metastable hexagonal reflection appears and becomes predominant, where the stress/strain curve still shows a plateau deformation. With a further increase of the strain, the intensity of the hexagonal reflection peak begins to decrease and subsequently that of the usual orthorhombic ones increase. Correspondingly, a rapid increase of draw stress, because of the strain‐hardening behavior, is recorded.

Stacked line profiles extracted from in situ WAXD patterns along the equatorial direction. The red profile was obtained at the critical time of 162.5 s.     

Influence of the molecular architecture of low‐density polyethylene on the texture and mechanical properties of blown films

Three types of low‐density polyethylene materials were investigated with respect to the influence of the molecular architecture on the mechanical and use properties of blown films. The materials were a branched polyethylene synthesized by free‐radical polymerization under high‐pressure (HP‐LDPE), a linear ethylene–hexene copolymer (ZN‐LLDPE) produced by low‐pressure Ziegler–Natta catalysis, and an ethylene–hexene copolymer (M‐LLDPE) from metallocene catalysis. The extrusion and blowing conditions were identical for the three materials, with a take‐up ratio of 12 and a blow‐up ratio of 2.5. The blown films displayed a decreasing puncture resistance in the order M‐LLDPE, ZN‐LLDPE, and HP‐LDPE. In parallel, the tear resistance of the films became increasingly unbalanced in the same order of the polymers. The morphological study showed an increased anisotropy of the films in the same polymer order, the crystalline lamellae being increasingly oriented normal to the take‐up direction. This texturing caused a detrimental effect on the mechanical properties of the films, notably increasing the capacity for crack propagation. The phenomenon was ascribed to the kinetics of chain relaxation in the melt that governed the ability of the chains to recover an isotropic state from the flow‐induced stretching before crystallization. The puncture resistance was examined in terms of both texture and strain‐hardening capabilities. © 2003 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 327–340, 2003     

Synthesis and morphology of polyethylene chains grafted onto the surface of crosslinked polystyrene microspheres

The bifunctional comonomer 4‐(3‐butenyl) styrene was used to synthesize crosslinked polystyrene microspheres (c‐PS) with pendant butenyl groups on their surface via suspension copolymerization. Polyethylene chains were grafted onto the surface of c‐PS microspheres (PS‐g‐PE) via ethylene copolymerizing with the pendant butenyl group on the surface of the c‐PS microspheres under the catalysis of metallocene catalyst. The composition and morphology of the PS‐g‐PE microspheres were characterized by means of Fourier transform infrared spectroscopy, Fourier transform Raman spectroscopy, X‐ray photoelectron spectroscopy, and field‐emission scanning electron microscopy. It is possible to control the content of PE grafted onto the surface of c‐PS microspheres by varying the polymerization time or the initial quantity of pendant butenyl group on the surface of c‐PS microspheres. Investigation on the morphology and crystallization behavior of grafted PE chains showed that different surface patterns could be formed under various crystallization conditions. Moreover, the crystallization temperature of PE chains grafted on the surface of c‐PS microspheres was 6 °C higher than that of pure PE. The c‐PS microspheres decorated by PE chains had a better compatibility with PE matrix. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 4477–4486, 2007     

Crystallization and melting of isotactic polypropylene crystallized from quiescent melt and stress‐induced localized melt

Temperature dependency of crystalline lamellar thickness during crystallization and subsequent melting in isotactic polypropylene crystallized from both quiescent molten state and stress‐induced localized melt was investigated using small angle X‐ray scattering technique. Both cases yield well‐defined crystallization lines where inverse lamellar thickness is linearly dependent on crystallization temperature with the stretching‐induced crystallization line shifted slightly to smaller thickness direction than the isothermal crystallization one indicating both crystallization processes being mediated a mesomorphic phase. However, crystallites obtained via different routes (quiescent melt or stress‐induced localized melt) show different melting behaviors. The one from isothermal crystallization melted directly without significant changing in lamellar thickness yielding well‐defined melting line whereas stress‐induced crystallites followed a recrystallization line. Such results can be associated with the different extent of stabilization of crystallites obtained through different crystallization routes. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55, 957–963     

Analysis of the complex thermal behavior of poly(L‐lactic acid) film. I. Samples crystallized from the glassy state

The melting behavior of poly(L ‐lactic acid) film crystallized from the glassy state, either isothermally or nonisothermally, was studied by wide angle X‐ray diffraction (WAXD), small angle X‐ray scattering (SAXS), differential scanning calorimetry (DSC), and temperature‐modulated differential scanning calorimetry (TMDSC). Up to three crystallization and two melting peaks were observed. It was concluded that these effects could largely be accounted for on the basis of a “melt‐recrystallization” mechanism. When molecular weight is low, two melting endotherms are readily observed. But, without TMDSC, the double melting phenomena of high molecular weight PLLA is often masked by an exotherm just prior to the final melting, as metastable crystals undergo melt‐recrystallization during heating in the DSC. The appearance of a double cold‐crystallization peak during the DSC heating scan of amorphous PLLA film is the net effect of cold crystallization and melt‐recrystallization of metastable crystals formed during the initial cold crystallization. Samples cold‐crystallized at 80 and 90 °C did not exhibit a long period, although substantial crystallinity developed. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 3200–3214, 2006     

Interplay between solid state microstructure and photophysics for poly(9,9‐dioctylfluorene) within oriented polyethylene hosts

We present a study of isotropic and uniaxially oriented binary blend films comprising ≤1 wt % of the conjugated polymer poly(9,9‐dioctylfluorene) (PFO) dispersed in both ultra‐high molecular weight (UHMW) and linear‐low‐density (LLD) polyethylene (PE). Polarized absorption, fluorescence and Raman spectroscopy, scanning electron microscopy, and X‐ray diffraction are used to characterize the samples before and after tensile deformation. Results show that blend films can be prepared with PFO chains adopting a combination of several distinct molecular conformations, namely glassy, crystalline, and the so‐called β‐phase, which directly influences the resulting optical properties. Both PFO concentration and drawing temperature strongly affect the alignment of PFO chains during the tensile drawing of the blend films. In both PE hosts, crystallization of PFO takes place during drawing; the resulting ordered chains show optimal optical anisotropy. Our results clarify the PFO microstructure in oriented blends with PE and the processing conditions required for achieving the maximal optical anisotropy. © 2014 The Authors. Journal of Polymer Science Part B: Polymer Physics Published by Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 22–38     

Effect of strain‐induced molecular ordering on mechanical performance and barrier properties of polylactide nanocomposites

Plastic deformation of polylactide has been known as a self‐reinforcement alternative to improve mechanical and barrier properties. In this study, the structural evolution was investigated during a hot‐drawing process, at different initial strain rates and temperatures above T_g of polylactide. The drawing process at T_g +10 °C, led to the formation of an intermediate molecular ordering, between the crystalline and amorphous phases. A lower fraction of this mesomorphic phase was found to develop with the addition of nanoparticles. An increase in the stretching temperature to T_g +30 °C, caused an improvement of the crystallization kinetics, compared to that of thermally activated crystallization. A strain hardening behavior was observed in the presence of mesophase during a stretching process of the hot‐drawn films at room temperature. Permeability was discerned to its basic components, diffusivity, and solubility coefficients. The matrix degradation influenced the permeability components. The diffusivity decreases in the presence of the impermeable matters. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55, 1865–1876     

Relationship between fracture toughness and intrinsic deformation parameters in isotropic and flow‐oriented linear low‐density polyethylene

The fracture toughness of isotropic and flow‐oriented linear low‐density polyethylene (LLDPE) is evaluated by the Essential Work of Fracture (EWF) concept, with a special setup of CCD camera to monitor the process of deformation. Allowing for the molecular orientation, flow‐oriented sample, prepared via melt extrusion drawing, is stretched parallel (oriented‐0°) and perpendicular (oriented‐90°) to its original melt extrusion drawing direction, respectively. The obtained values of specific EFW w_e are 34.6, 10.2, and 4.2 N/mm for the oriented‐0°, isotropic and oriented‐90° sample, respectively. With knowledge of intrinsic deformation parameters deduced from uniaxial tensile tests, moreover, a relationship between specific EFW w_e the ratio of true yield stress to strain hardening modulus σ_ty/G is well established. It means that the fracture toughness of polyethylene is determined by both crystalline and amorphous parts, rather than by one of them. Moreover, the true yield stress seems to be nondecisive factors determining the fracture toughness of polyethylene. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 2880–2887, 2006     

Structural arrangement of crystalline/amorphous phases of polyethylene‐block‐polystyrene copolymer as induced by orientation techniques

A polyethylene‐block‐polystyrene copolymer film having a bicontinuous crystalline/amorphous phases was tensile‐drawn under various conditions for the structural arrangement of these phases. The prepared film could be drawn below the melting temperature of the polyethylene component, with the highest drawability obtained at 60°C. However, the initial bicontinuous structure was gradually destroyed with increasing strain because the drawing temperature was lower than the glass‐transition temperature of the polystyrene component. Correspondingly, a necking phenomenon was clearly recognizable when samples were drawn. In contrast, drawing near the melting temperature of the polyethylene component produced less orientation of both the crystalline and amorphous phases, resulting in homogeneous deformation with lower drawing stress. These results indicated that the modification of the lower ductility of the polystyrene component was key to the effective structural arrangement of both phases by tensile drawing. Here, a solvent‐swelling technique was applied to improve polystyrene deformability even below its glass‐transition temperature. Tensile drawing after such a treatment successfully induced the orientation of both the crystalline and amorphous phases while retaining their initial continuities. A change in the deformation type from necking to homogeneous deformation was also confirmed for the stress–strain behavior. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 1731–1737, 2006     

Crystallization of polyamide confined in sub‐micrometer droplets dispersed in a molten polyethylene matrix

The crystallization of submicrometer PA6 droplets dispersed in an ethylene‐1‐octene copolymer matrix, using PE‐g‐MA as a compatibilizer agent, is investigated. This system shows a nonconventional mechanical behavior at high temperatures. Up to ～100 °C above the final melting temperature of the ethylene‐1‐octene copolymer matrix, the system shows good thermal and mechanical properties including dimensional stability. Because of the dispersed phase morphology of the system, so‐called fractionated/homogeneous crystallization takes place leading to an extra supercooling of PA6: ～50 °C compared to the bulk PA6 crystallization temperature. Thus—though this is most probably just of interest for small‐scale research—the system can be processed at lowered temperatures while still providing exceptional high‐temperature properties. While the matrix is in the melt state when crystallization of the dispersed PA6 phase occurs, the possibility of matrix induced crystallization is absent, contrary to almost all of the ‘dispersed droplets in a matrix’ systems reported so far. The kinetics of this phenomenon is investigated in detail by DSC: the existence of fractionated/homogeneous crystallization is shown to be related to the lack of active nuclei in the dispersed droplets by means of self‐seeding experiments. The occurrence of extensive cold crystallization of PA6 in the confined environment is studied as is the crystallization kinetics, including the characterization of its time dependences showing its sporadic nature. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 815–825, 2006     

Biodegradable fibers of poly(3‐hydroxybutyrate) produced by high‐speed melt spinning and spin drawing

The effects of high‐speed melt spinning and spin drawing on the structure and resulting properties of bacterial generated poly(3‐hydroxybutyrate) (PHB) fibers were investigated. The fibers were characterized by their degree of crystallinity by differential scanning calorimetry (DSC) and wide‐angle X‐ray scattering (WAXS), their orientation by WAXS, and the textile physical properties. The WAXS studies revealed that the fibers spun at high speeds and high draw ratios possessed orthorhombic (α modification) and hexagonal (β modification) crystals, the latter as a result of stress‐induced crystallization. The fiber structures formed during these processes were fibril‐like as the atomic force microscopy images demonstrated. The maximum physical break stress, the modulus, and the elongation at break observed in the fibril‐like spin drawn fibers were about 330 MPa, 7.7 GPa, and 37%, respectively. The fibers obtained by a low draw ratio of 4.0 had spherulitic structures and poor textile physical properties. The PHB pellets were analyzed by their degradation during the processes of drying and spinning and by their thermal and rheological properties. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 2841–2850, 2000     

Nonisothermal crystallization and melting behavior of syndiotactic polypropylenes of different microstructure

Syndiotactic polypropylenes and their copolymers with 1‐olefins were synthesized using two metallocene/MAO catalytic systems, and the effect of the different microstructures on nonisothermal crystallization and subsequent melting was studied. Using differential scanning calorimetry (DSC) it was observed that samples with lower content of defects showed crystallization on cooling from the melt, and a double melting peak in the subsequent heating scan, the latter associated with melt, recrystallization and remelt processes that it was confirmed by its nonreversing exothermic process found by means of temperature modulated DSC (MDSC). However, polymers with high amount of defects showed cold crystallization on heating followed by a melting process, that it was observed by MDSC. Wide angle X‐ray diffraction was used for characterizing the changes of crystalline forms in relationship with crystallization process. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 798–806, 2008     

Nucleation and overgrowth of PE on PTFE/iPP interfaces

Using an experimental setup with a three‐phase intersecting boundary of PTFE/PE/iPP, the nucleation power of PTFE compared to iPP on the PE was studied by TEM. It was found that the nucleation of the PE on the PTFE interface started at a higher temperature than epitaxial nucleation of the PE onto the iPP interface. During cooling of the melt, the growth direction of the PE crystalline lamellae changes in a continuous manner from the transcrystallization direction of the PTFE/PE interface into the heteroepitaxial “crosshatched” orientation of the iPP/PE interface. A (still highly speculative) self‐assembly of the PE macromolecules at the respective interface just in front of the actual crystallization edge is used to explain this observed phenomenon. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 80–83, 2000     

AlR2Cl/MgR2 combinations as universal cocatalysts for Ziegler–Natta,metallocene, and post‐metallocene catalysts

Combinations of dialkylaluminum chlorides and dialkylmagnesium compounds, when used at molar [AlR₂Cl]:[MgR₂] ratios ≥ 2, act as universal cocatalysts for all three presently known types of alkene polymerization catalysts—Ziegler–Natta, metallocene, and post‐metallocene. When these cocatalysts are used with supported Ti‐based Ziegler–Natta catalysts, they produce catalyst systems which are 1.5–2 times more active than the systems utilizing AlR₃ compounds as cocatalysts. Combinations of AlR₂Cl/MgR₂ cocatalysts and various metallocene complexes produce single‐center catalyst systems similar to those formed in the presence of MAO. The same cocatalysts activate numerous post‐metallocene Ti complexes containing bidentate ligands of a different nature and produce multicenter systems of very high activity. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 3271–3285, 2009