Morphological comparison of isotactic polypropylene parts prepared by micro‐injection molding and conventional injection molding

The morphological feature of microparts evolved during micro‐injection molding may differ from that of the macroparts prepared by conventional injection molding, resulting in specific physical properties. In this study, isotactic polypropylene (iPP) microparts with 200 µm thickness and macroparts with 2000 µm thickness were prepared, and their morphological comparison was investigated by means of polarized light microscopy (PLM), scanning electron microscopy (SEM), differential scanning calorimeter (DSC), and wide‐angle X‐ray diffraction (WAXD). The results presented some similarities and differences. PLM observations showed that the through‐the thickness‐morphology of micropart exhibited a similar “skin–core” structure as macropart, but presented a large fraction of shear layer in comparison to the macropart which presented a large fraction of core layer. The SEM observation of shear layer of micropart featured highly oriented shish‐kebab structure. The micropart had a more homogeneous distribution of lamellae thickness. The degree of crystallinity of the micropart was found to be higher than that of the macropart. High content of β‐crystal was found in micropart. The 2D WAXD pattern of the core layer of macropart showed full Debye rings indicating a random orientation, while the arcing of the shear layer indicates a pronounced orientation. The most pronounced arcing of the micropart indicates the most pronounced orientation of iPP chains within lamellae. Copyright © 2011 John Wiley & Sons, Ltd.     

Crystallization of polylactic acid under in situ deformation during nonsolvent‐induced phase separation

In this study, we investigate polylactic acid (PLA) crystallization under in situ biaxial extension in a nonsolvent‐induced phase separation foaming process. Our ternary system consists of PLA, dichloromethane (DCM) as solvent and hexane as nonsolvent. For the first time, the formation of a shish‐kebab crystalline morphology is observed in such a solution‐based foaming process in certain solid–liquid phase separated systems. The formation of shish‐kebabs is described based on the coil‐stretch transition concept. The rapid biaxial deformation caused by macropore growth uniaxially stretches the long chains that are tied with at least two single crystals which eventually leads to the formation of shish structures throughout the polymer‐rich phase. The kebab lamellae then form perpendicularly on the shish cores. The scanning electron microscopy (SEM) observations and our interpretation of the crystallization phenomena are confirmed by differential scanning calorimetry (DSC) analysis. The observation of various crystalline morphologies, particularly shish‐kebabs, and the elucidation of their formation mechanisms contribute to the understanding of phase separation and pore growth as well as crystallization in such polymer–solvent–nonsolvent systems. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55, 1055–1062     

Integrated mechanism for the morphological structure development in HDPE melt‐blown and machine‐direction‐oriented films

The morphologies of a series of blown films and machine‐direction‐oriented (MDO) films, all produced from high density polyethylene, were characterized. In the blown film process, the crystalline morphology develops while the melt is under extensional stress. In the MDO process, drawing takes place in the solid state and deforms the crystalline morphology of the starting film. The films were characterized by wide‐angle X‐ray scattering (WAXS), small‐angle X‐ray scattering (SAXS) and atomic force microscopy to determine the lamellar morphology. The effect of the type of deformation on the lamellar morphology was studied and relationships were developed between the lamellar and polymer chain morphology using SAXS and WAXS. Blown and MDO films were found to have very different morphologies. However, an integrated mechanism was developed linking the sequential events in the deformation and morphology development in blown and MDO films. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 1834–1844, 2007     

Confirmation of a nanohybrid shish‐kebab (NHSK) structure in composites of PET and MWCNTs

Here, the confirmation of an oriented nanohybrid shish‐kebab (NHSK) crystalline structure in a series of composites of poly(ethylene terephthalate) (PET) and multiwall carbon nanotubes (MWCNTs) is reported. The combined use of small‐ and wide‐angle X‐ray scattering (SAXS/WAXS) and thermal analysis has been used to investigate the morphology development in PET‐MWCNT nanocomposites under hot isothermal crystallization conditions. The MWCNTs act as both heterogeneous nucleating agents and surfaces (oriented shish structures) for the epitaxial growth of PET crystallites (kebabs) giving an oriented crystalline morphology. In contrast, the PET homopolymer does not show any residual oriented crystalline morphology during isothermal crystallization but gave a sporadic nucleation of a classic unoriented lamellar structure with slower crystallization kinetics. The results provide a valuable insight into the role of MWCNTs as nanoparticulate fillers in the morphology development and subsequent modification of physical properties in engineering polymers. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2017 , 55, 132–137     

Structure Evolution upon Uniaxial Drawing Skin‐ and Core‐Layers of Injection‐Molded Isotactic Polypropylene by In Situ Synchrotron X‐ray Scattering

The structure evolution of the oriented layer (skin) and unoriented layer (core) from injection‐molded isotactic polypropylene samples upon uniaxial drawing is probed by in situ synchrotron X‐ray scattering. The X‐ray data analysis approach, called “halo method”, is used to semiquantitatively identify the transformation process of crystal phase upon uniaxial drawing. The results verify the validation of the stress‐induced crystal fragmentation and recrystallization process in the deformation of the injection‐molded samples under different temperatures. Furthermore, the end of strain softening region in the engineering stress‐strain curves explicitly corresponds to the transition point from the stress‐induced crystal fragmentation to recrystallization process. Basically, the skin and core layers of the injection‐molded parts share the similar deformation mechanism as aforementioned. The stretching temperature which dramatically affects the relative strength between the entanglement‐induced tie chains and the adjacent crystalline lamellae determines the crystal structural evolution upon drawing. © 2013 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2013, 51, 1618–1631     

Stratified morphology of a polypropylene/elastomer blend following channel flow

A thermoplastic olefin blend consisting of isotactic polypropylene (PP) and an ethylene‐butene copolymer (EBR) impact modifier (25 wt % EBR) was subjected to a short, high‐shear pulse within the flow channel of a pressure‐driven microextruder following low‐shear channel filling from a reservoir of the melt. The resulting morphology was examined by laser scanning confocal fluorescence microscopy (LSCFM), with contrast provided by a fluorescent tracer in the EBR minor phase. Shear experiments were performed under isothermal conditions with a known wall shear stress for a specified duration, providing a well‐defined thermal and flow history. Low‐shear channel filling produces small droplets across the central region of the channel and large droplets, consistent with steady‐state shear, in the regions near the channel walls. After cooling the molten blend to a crystallization temperature of 153 °C, a brief interval (5 s ～ 1/2000 of the quiescent crystallization time) of high shear (wall shear stress: 0.1 MPa) induces rapid, highly oriented crystallization and a stratified morphology. Ex situ LSCFM reveals a “skin” at the channel walls (～70 μm) in which greatly elongated fiberlike droplets, oriented along the flow direction, are embedded in highly oriented crystalline PP. Further from the walls but directly beside the skin layers are surprising zones in which EBR domains show no deformation or orientation. Several zones of intermediate deformation and orientation at an angle to the flow direction are located closer to the center of the channel. At the center of the channel, EBR droplets are spherical, as expected for channel flow. The various strata are explained by the interplay of droplet deformation, breakup, and coalescence with the shear‐induced crystallization kinetics of the matrix. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 2842–2859, 2002     

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     

Flexible transparent fluorinated nanohybrid with innovative heat‐resistance property—new technology proposal for fabrication of transparent materials using “crystalline” polymer

A new technology for the production of transparent material, using a “crystalline” polymer, is proposed in this study. In addition, a heat‐resistant transparent flexible plastic film with a high hydrophobic surface and a thermal decomposition temperature near 400 °C was created. Partially fluorinated crystalline polymer with switchboard‐type lamellae results high transparency as a consequence of the formation of a high‐density amorphous structure based on high‐temperature drawing just below the melting point at 250 °C. Melt‐compounding with montmorillonite modified by the long‐chain quaternary phosphonium with high coverage induces formation of a nanohybrid that retains transparency and also results in an increase in the thermal degradation temperature by over 50 °C. Through this technology, which results in heat‐resistance, transparency, and flexibility, the nano‐micro‐millimeter structures of solid‐state polymers are hierarchically controlled, which enables the creation of new materials. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 1674–1690     

Morphology control of polypropylene by crystallization under carbon dioxide

We investigated the crystalline morphology of isotactic polypropylene obtained by melt crystallization under carbon dioxide (CO₂) at various pressures. Spherulites consisting of regularly arranged fibrils without subsidiary lamellae were obtained by crystallization under CO₂ below 2 MPa, whereas large spherulites consisting of irregularly arranged fibrils with subsidiary lamellae were obtained under ambient pressure. Distorted domain crystals with uniform optical anisotropy consisting of α‐form were found to be obtained under CO₂ above 2 MPa, and needle crystals consisting of γ‐form were obtained above 12 MPa. Transmission electron micrographs showed that straight and thick lamellae are regularly arranged in both the distorted domain crystals and the needle crystals. The uniformly thick lamellae were confirmed by differential scanning calorimetry thermograms; that is, the melting temperature is higher and the melting peak is sharper than those obtained under ambient pressure. Such characteristic crystalline morphologies obtained under CO₂ may be attributed to local ordering in the melt state. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 2738–2746, 2004     

Crystallization behavior of isotactic propylene‐1‐hexene random copolymer revealed by time‐resolved SAXS/WAXD techniques

The crystallization behavior of isotactic propylene‐1‐hexene (PH) random copolymer having 5.7% mole fraction of hexene content was investigated using simultaneous time‐resolved small‐angle X‐ray scattering (SAXS) and wide‐angle X‐ray diffraction (WAXD) techniques. For this copolymer, the hexene component cannot be incorporated into the unit cell structure of isotactic polypropylene (iPP). Only α‐phase crystal form of iPP was observed when samples were melt crystallized at temperatures of 40 °C, 60 °C, 80 °C, and 100 °C. Comprehensive analysis of SAXS and WAXD profiles indicated that the crystalline morphology is correlated with crystallization temperature. At high temperatures (e.g., 100 °C) the dominant morphology is the lamellar structure; while at low temperatures (e.g., 40 °C) only highly disordered small crystal blocks can be formed. These morphologies are kinetically controlled. Under a small degree of supercooling (the corresponding iPP crystallization rate is slow), a segmental segregation between iPP and hexene components probably takes place, leading to the formation of iPP lamellar crystals with a higher degree of order. In contrast, under a large degree of supercooling (the corresponding iPP crystallization rate is fast), defective small crystal blocks are favored due to the large thermodynamic driving force and low chain mobility. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 48: 26–32, 2010     

Crystalline structure and morphology of microphases in compatible mixtures of poly(tetrahydrofuran‐methyl methacrylate) diblock copolymer and polytetrahydrofuran

The crystalline structure and morphology of compatible mixtures of poly(tetrahydrofuran‐methyl methacrylate) diblock copolymers (PTHF‐b‐PMMA) with a polytetrahydrofuran homopolymer (PTHF) were studied with synchrotron X‐rays. Wide‐angle diffraction was used to study the crystalline structures in a confined lamellar region with a PTHF thickness ranging from 12.2 to 19.5 nm, and in a PTHF matrix with an interface distance between the PMMA cylinders ranging from 17 to 22 nm. As the above thickness values are around the long period (ca. 17 nm) of PTHF homopolymer under the crystallization condition used, the crystalline structure has been found to be very sensitive to the average thickness of the PTHF phase. The changes in the diffraction patterns with changing PTHF homopolymer content suggested a chain folding model in confined PTHF lamellae with the PTHF fiber axes being perpendicular to the thick PTHF lamella. In the case of hexagonally packed cylindrical PMMA microdomains with an interface distance ranging from 12 to 16 nm, the effects of PMMA cylinders on the crystallization morphology of PTHF in the PTHF matrix, and the effects of the PTHF crystallization on the hexagonally packed structure of PMMA cylinders were also studied. It is shown that only when the interdistance of two neighboring PMMA cylinders is comparable with the long period of the pure PTHF homopolymer, ordered PTHF stacks can be formed in the PTHF matrix. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 779–792, 1999     

Recent advances in the solution self‐assembly of amphiphilic “rod‐coil” copolymers

Solution self‐assembly of amphiphilic “rod‐coil” copolymers, especially linear block copolymers and graft copolymers (also referred to as polymer brushes), has attracted considerable interest, as replacing one of the blocks of a coil‐coil copolymer with a rigid segment results in distinct self‐assembly features compared with those of the coil‐coil copolymer. The unique interplay between microphase separation of the rod and coil blocks with great geometric disparities can lead to the formation of unusual morphologies that are distinctly different from those known for coil‐coil copolymers. This review presents the recent achievements in the controlled self‐assembly of rod‐coil linear block copolymers and graft copolymers in solution, focusing on copolymer systems containing conjugated polymers, liquid crystalline polymers, polypeptides, and polyisocyanates as the rod segments. The discussions concentrate on the principle of controlling over the morphology of rod‐coil copolymer assemblies, as well as their distinctive optical and optoelectronic properties or biocompatibility and stimuli‐responsiveness, which afford the assemblies great potential as functional materials particularly for optical, optoelectronic and biological applications. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2017 , 55, 1459–1477     

Structure and morphology control in thin films of regioregular poly(3‐hexylthiophene)

This review focuses on the structural control in thin films of regioregular poly(3‐hexylthiophene) (P3HT), a workhorse among conjugated semiconducting polymers. It highlights the correlation existing between processing conditions and the resulting structures formed in thin films and in solution. Particular emphasis is put on the control of nucleation, crystallinity and orientation. P3HT can generate a large palette of morphologies in thin films including crystalline nanofibrils, spherulites, interconnected semicrystalline morphologies and nanostructured fibers, depending on the elaboration method and on the macromolecular parameters of the polymer. Effective means developed in the recent literature to control orientation of crystalline domains in thin films, especially by using epitaxial crystallization and controlled nucleation conditions are emphasized. © 2011 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 49: 1218–1233, 2011     

Dielectric and thermal characterization of low density ethylene/10‐undecen‐1‐ol copolymers prepared with nickel catalysts

Ethylene and 10‐undecen‐1‐ol copolymers, prepared using a nickel complex as catalyst, were studied using differential scanning calorimetry (DSC), X‐ray diffraction, and dielectric relaxation spectroscopy. The behavior exhibited by copolymers containing incorporated 10‐undecen‐1‐ol amounts within 0.5 and 4.6 mol % was compared with neat polyethylene. DSC revealed that a new crystalline region with lower thickness lamellae emerges in copolymers due to the side‐chains crystallization. Nevertheless, the global crystallization degree decreases due to the loss of crystallinity that occurs in a greater extent in PE‐like regions. Dielectric relaxation spectroscopy detected two processes, a low activation energy process below ?20 °C related with localized mobility increasing in intensity and deviating to higher temperatures with the increase in 10‐undecen‐1‐ol amount, and a high activation energy process ascribed to the glass transition, located at higher temperatures for the different copolymers relatively to neat polyethylene. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 2802–2812, 2007     

Topological “interfacial” polymer chemistry: Dependency of polymer “shape” on surface morphology and stability of layer structures when heating organized molecular films of cyclic and linear block copolymers of n‐butyl acrylate‐ethylene oxide

The “topological polymer chemistry” of amphiphilic linear and cyclic block copolymers at an air/water interface was investigated. A cyclic copolymer and two linear copolymers (AB‐type diblock and ABA‐type triblock copolymers) synthesized from the same monomers were used in this study. Relatively stable monolayers of these three copolymers were observed to form at an air/water interface. Similar condensed‐phase temperature‐dependent behaviors were observed in surface pressure–area isotherms for these three monolayers. Molecular orientations at the air/water interface for the two linear block copolymers were similar to that of the cyclic block copolymer. Atomic force microscopic observations of transferred films for the three polymer types revealed the formation of monolayers with very similar morphologies at the mesoscopic scale at room temperature and constant compression speed. ABA‐type triblock linear copolymers adopted a fiber‐like surface morphology via two‐dimensional crystallization at low compression speeds. In contrast, the cyclic block copolymer formed a shapeless domain. Temperature‐controlled out‐of‐plane X‐ray diffraction (XRD) analysis of Langmuir–Blodgett (LB) films fabricated from both amphiphilic linear and cyclic block copolymers was performed to estimate the layer regularity at higher temperatures. Excellent heat‐resistant properties of organized molecular films created from the cyclic copolymer were confirmed. Both copolymer types showed clear diffraction peaks at room temperature, indicating the formation of highly ordered layer structures. However, the layer structures of the linear copolymers gradually disordered when heated. Conversely, the regularity of cyclic copolymer LB multilayers did not change with heating up to 50 °C. Higher‐order reflections (d₀₀₂, d₀₀₃) in the XRD patterns were also unchanged, indicative of a highly ordered structure. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2016 , 54, 486–498     

Effect of in situ poly(ethylene terephthalate) (PET) microfibrils on the morphological structure and crystallization behavior of isotactic polypropylene (iPP) under an intensive shear rate

The morphological structure and crystallization behavior of in situ poly(ethylene terephthalate) (PET)/isotactic polypropylene (iPP) microparts prepared through micro‐injection molding are investigated using a polarized light microscope, differential scanning calorimeter, scanning electron microscope, and two‐dimensional wide‐angle X‐ray. Results indicate that both the shear effect and addition of PET fibers greatly influence the morphologies of the iPP matrix. Typical “skin‐core” and oriented crystalline structures (shish‐kebab) may simultaneously be observed in neat iPP and iPP/PET microparts. The presence of PET phases reveals significant nucleation ability for iPP crystallization. High concentrations of PET phases, especially long PET fibers, correspond to rapid crystallization of the iPP matrix. The occurrence of PET microfibrils decreases the content and size of β‐crystals; by contrast, the orientation degree of β‐crystals increases with increasing PET content in the microparts. This result suggests that the existence of the microfibrillar network can retain the ordered clusters and promote the development of oriented crystalline structures to some extent. Copyright © 2015 John Wiley & Sons, Ltd.     

Multiple morphologies of the aggregates from self‐assembly of diblock copolymer with relatively long corona‐forming block in dilute aqueous solution

Reported here is self‐assembly behavior in selective solvent of diblock copolymers with relatively long corona‐forming block compared to core‐forming block. Three diblock copolymers, poly(ethylene glycol) monomethyl ether‐b‐poly(methacryloyl‐L ‐leucine methyl ester), also denoted as MPEG‐b‐PMALM copolymer, were prepared by fixing MPEG block with an average number of repeating units of 115, whereas varying PMALM block with an average number of repeating unit of 44, 23, 9, respectively. Multiple morphologies, such as sphere, cylinder, vesicle, and their coexisted structures from self‐assembly of these diblock copolymers in aqueous media by changing block nonselective solvent and initial polymer concentration used in preparation, were demonstrated directly via TEM observation. These results herein might, therefore, demonstrate as an example that a wide range of morphologies can be accessed not only from “crew‐cut micelles” but also from “star‐micelles” by controlling over preparation strategies. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 48: 364–371, 2010     

Oxygen‐barrier properties of cold‐crystallized and melt‐crystallized poly(ethylene terephthalate‐co‐4,4′‐bibenzoate)

This study examined the oxygen‐transport properties of poly(ethylene terephthalate‐co‐bibenzoate) (PETBB55) crystallized from the melt (melt crystallization) or quenched to glass and subsequently isothermally crystallized by heating above the glass‐transition temperature (cold crystallization). The gauche–trans conformation of the glycol linkage was determined by infrared analysis, and the crystalline morphology was examined by atomic force microscopy. Oxygen solubility decreased linearly with volume fraction crystallinity. For melt‐crystallized PETBB55, extrapolation to zero solubility corresponded to an impermeable crystal with 100% trans glycol conformations, a density of 1.396 g cm^?3, and a heat of melting of 83 J g^?1. From the melt, PETBB55 crystallized as space‐filling spherulites with loosely organized lamellae and pronounced secondary crystallization. The morphological observations provided a structural model for permeability consisting of impermeable platelets randomly dispersed in a permeable matrix. In contrast, cold‐crystallized PETBB55 retained the granular texture of the quenched polymer despite the high level of crystallinity, as measured by the density and heat of melting. Oxygen solubility decreased linearly with volume fraction crystallinity, but zero solubility corresponded to an impermeable defective crystal with a trans fraction of 0.83 and a density of 1.381 g cm^?3. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 2489–2503, 2002