Solid-state coextrusion of high-density polyethylene. I. Effects of geometric factors

The solid (crystalline) state coextrusion of two high-density polyethylenes (HDPE) having weight-average molecular weights (M_w) of 59,000 and 200,000 have been studied as a function of the geometrical arrangement and the volume fraction of the components. The extrusion rate increased nonlinearly with the volume fraction of the low-M_w, component. The rate was faster when the low-M_w, component was the core rather than the sheath in the initial cylindrical concentric billet. Thus the slow extrusion rate of high-M_w HDPE alone was increased up to ten times by coextrusion with a small fraction of the low-M_w, HDPE component in its center. Generally, the deformation flow profile changed gradually from a parabolic to a W-shaped pattern as the volume fraction of the high-M_w, component increased. However, the geometric arrangement of the two different M_w components also had a pronounced effect on the deformation. The deformation patterns showed that upon coextrusion the low- and high-M_w HDPE's were extruded at the same rate and extrusion draw ratio. The geometrical arrangement had no substantial effects on the tensile modulus and strength of the extrudates; i.e., they increased linearly with volume fraction of the high-M_w HDPE.     

Tensile strength of highly oriented polyethylene. II. Effect of molecular weight distribution

The tensile strength of oriented polyethylene filaments is discussed in relation to molecular weight. Short-term tensile properties at room temperature were obtained in our laboratory and from the literature for polymer samples covering the molecular weight (M _w) range from 54 × 10³ to 4 × 10⁶, and polydispersities ranging from 1.1 to 15.6, oriented by solid-state extrusion, melt spinning/drawing, solution spinning/drawing, and “surface growth.” It was found that both the molecular weight and its distribution markedly affected tensile strength. The breaking stress σ of highly oriented fibers varied with molecular weight roughly as σ ∝, M^0.4, at constant M _w/M _n over the entire range studied. Reduction of polydispersity from 8 to 1.1 by an increase of M _n with M _w approximately constant at 10⁵ increased tensile strength of oriented polyethylene filaments by a factor of nearly 2.     

Maximum tensile properties of oriented polyethylene,achieved by uniaxial drawing of solution‐grown crystal mats: Effects of molecular weight and molecular weight distribution

The effects of molecular weight (MW) and MW distribution on the maximum tensile properties of polyethylene (PE), achieved by the uniaxial drawing of solution‐grown crystal (SGC) mats, were studied. The linear‐PE samples used had wide ranges of weight‐average (M_w = 1.5–65 × 10⁵) and number‐average MWs (M_n = 2.0–100 × 10⁴), and MW distribution (M_w/M_n = 2.3–14). The SGC mats of these samples were drawn by a two‐stage draw technique, which consists of a first‐stage solid‐state coextrusion followed by a second‐stage tensile drawing, under controlled conditions. The optimum temperature for the second‐stage draw and the resulting maximum‐achieved total draw ratio (DR_t) increased with the MW. For a given PE, both the tensile modulus and strength increased steadily with the DR_t and reached constant values that are characteristic for the sample MW. The tensile modulus at a given DR_t was not significantly affected by the MW in the lower DR_t range (DR_t < 50). However, both the maximum achieved tensile modulus (80–225 GPa) and strength (1.0–5.6 GPa), as well as those at higher DR_ts > 50, were significantly higher for a higher MW. Although the maximum modulus reached 225 ± 5 for M_n ≥ 4 × 10⁵, the maximum strength continued to increase with M_n even for M_n > 4 × 10⁵, showing that strength is more strongly dependent on the M_n, even at higher M_n. Furthermore, it was found that each of the maximum tensile modulus and strength achieved could be expressed by a unique function of the M_n, independently of the wide variations of the sample MW and MW distribution. These results provide an experimental evidence that the M_n has a crucial effect on the tensile properties of extremely drawn and chain‐extended PE fibers, because the structural continuity along the fiber axis increases with the chain length, and hence with the M_n. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 153–161, 2006     

Plastic deformation of polypropylene: Effect of molecular weight on drawing behavior and structural characteristics of ultra-high-modulus products

The influence of molecular weight and temperature on the tensile drawing behavior of polypropylene has been studied, with particular reference to the production of ultra-high-modulus oriented materials. It has been shown that the optimum draw temperature is molecular weight independent to a good approximation, and that high-modulus products can be obtained for M?_w in the range 180,000–400,000, the highest modulus being achieved for polymer with M?_w = 181,000. As in the case of linear polyethylene, under optimum drawing conditions the Young's modulus relates only to the draw ratio. Low-temperature moduli as high as 25–27 GPa were recorded, which compare favorably with a previously reported value of 42 GPa for the crystal-lattice modulus. Although the drawing behaviour of the samples studied appeared comparatively insensitive to molecular weight, some of the properties of the draw materials, notably melting point and shrinkage at high temperature, showed a wide range of behavior.     

Superdrawing of polytetrafluoroethylene nascent powder by solid‐state coextrusion

A film of nascent powder of polytetrafluoroethylene (PTFE), compacted below the ambient melting temperature (T_m, 335 °C), was drawn by two‐stage draw techniques consisting of a first‐stage solid‐state coextrusion followed by a second‐stage solid‐state coextrusion or tensile draw. Although the ductility of extrudates was lost for the second‐stage tensile draw at temperatures above 150 °C due to the rapid decrease in strength, as previously reported, the ductility of extrudates increased with temperature even above 150 °C when the second‐stage draw was made by solid‐state coextrusion, reflecting the different deformation flow fields in a free space for the former and in an extrusion die for the latter. Thus, a powder film initially coextruded to a low extrusion draw ratio (EDR) of 6–20 at 325 °C was further drawn by coextrusion to EDRs up to ～?400 at 325–340 °C, near the T_m. Extremely high chain orientation (f_c = 0.998 ± 0.001), crystallinity (96.5 ± 0.5)%, and tensile modulus (115 ± 5 GPa at 24 °C, corresponding to 73% of the X‐ray crystal modulus) were achieved at high EDRs. Despite such a morphological perfection and a high modulus, the tensile strength of a superdrawn tape, 0.48 ± 0.03 GPa, was significantly low when compared with those (1.4–2.3 GPa) previously reported by tensile drawing above the T_m. Such a low strength of a superdrawn, high‐modulus PTFE tape was ascribed to the low intermolecular interaction of PTFE and the lack of intercrystalline links along the fiber axis, reflecting the initial chain‐extended morphology of the nascent powder combined with the fairly high chain mobility associated with the crystal/crystal transitions at around room temperature. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 3369–3377, 2006     

Influence of initial polymer concentration in solution and weight-average molecular weight on the drawing behavior of polyethylenes

The influence of initial polymer concentration in solution (c), weight-average molecular weight (M_ω), and drawing temperature on the solid-state drawing behavior of linear polyethylenes was investigated. Optimum conditions, with respect to maximum attainable draw ratio, are observed in isothermal drawing experiments. Moreover, it is shown that high maximum attainable draw ratios can also be obtained upon multistage drawing of UHMW-PE (ultrahigh-molecular-weight polyethylene, M_ω > 10⁶ g/mol) gel films cast from concentrated solutions. The high maximum attainable draw ratio in combination with the high molecular weight (M_ω > 10⁶ g/mol) and polymer concentration (c = 10% w/v) is of particular interest because it results in tapes or fibers with a high Young's modulus (100 GPa) and tensile strength (2.5–3.5 GPa). It is also shown that the maximum attainable draw ratio of polyethylenes scales with the Bueche parameter (c · M_ω) to the ?0.5 power. This experimental observation indicates that intermolecular interactions not only dominate the rheological properties of polyethylene melts and concentrated solutions, but also strongly influence the solid-state drawing behavior of linear polyethylenes.     

Solid-state coextrusion of poly(ethylene terephthalate). I. Drawing of amorphous PET

Films of uniaxially oriented poly(ethylene terephthalate) (PET), M _v = 81,000, have been drawn by solid-state coextrusion in the range 40–100°C surrounded by polyethylene. This is well below the PET melting temperature and in some cases below its glass transition temperature. Properties of the extrudates, such as degree of crystallinity, mechanical and thermal properties, were investigated as a function of coextrusion temperature and draw ratio (EDR ≤ 4.4). The results show that the percent crystallinity depends strongly on draw ratio, whereas its sensitivity to extrusion temperature is limited only to the highest draw ratio (4.4). On the other hand, Young's modulus was sensitive to both extrusion temperature and draw ratio, exhibiting a maximum at EDR = 4.4 and T_ext = 65°C. Above this temperature, moduli decrease apparently because of increased chain mobility, resulting in dissipation of chain orientation. Furthermore, changes in yield and tensile strength followed the changes in mechanical properties, suggesting that they are dominated by the same factors. The cold-crystallization temperature T_CC also revealed information about the morphological changes occurring during the extrusion drawing. For samples of EDR = 4.4, T_CC increased with extrusion temperature, suggesting again dissipation of orientation by thermal motions. On the other hand, T_CC decreases with EDR, and a ΔT_CC as high as 73°C was found. Conventional drawing of amorphous PET has been widely reported. To our knowledge this is the first time oriented PET has been prepared using the advantages of solid-state coextrusion.     

Molecular weights and molecular weight distribution of polymers by equilibrium ultracentrifugation. Part II. Molecular weight distribution

A method has been developed for determining the molecular weight distribution of a polymer sample from the sedimentation–diffusion equilibrium data for a solution under pseudo-ideal conditions. From some theoretical examples it appears that the method works well and that the molecular weight distribution can be determined with a reasonable degree of resolution. From three polymer samples (polyethylene, polystyrene, and polycaprolactam) the molecular weight distribution was determined in this way. The average molecular weights, M?_n, M?_w, M?_z, and M _z+1, calculated from these distribution functions agree well with those calculated directly from the equilibrium data.     

Solid-state extrusion of chain-extended polyethylene

Billets of chain-extended polyethylene were prepared from Alathon 7050 (M_w 59,000, M_n 19,000) in an Instron capillary rheometer by crystallization at a constant pressure of 460 MPa, at a series of teimperatures from 198 to 221°C corresponding to varying degrees of undercooling. This gives chain-extended morphologies with a range of crystallinites and lamellar thicknesses. The billets were then solid-state extruded at 100°C through a conical die with 20° entrance angle up to an extrusion draw ration 23.4. Thermal behavior was studied with differential scanning calorimetry. The orientation function measured by wide-angle x-ray diffraction showed higher orientation function measured by wide-angle x-ray diffraction showed higher orientation at equivalent draw ratio when the initial billets were crystallized at lower temperatures. Drawing efficiency, defined as the ratio of molecular draw ratio (from shrinkage) to extrusion draw ratio correspondingly increases, reaching a maximum of 0.71 in our solid-state extrusion. These studies show that highly chain-extended polyethylene, i.e., with few chain entanglements, draws poorly. Drawability was improved by increasing chain entanglements by lowering the crystallization temperature. Electron micrographs of fracture surface replicas of extrudates revealed the coexistence of undeformed, tilted, partially drawn lamellae and fibrillar structure consistent with the cahange of morphologies in Peterlin's model of plastic deformation.     

Ratios of average molecular weights and molecular weight distributions in polymers

If M_min and M_max are lower and upper bounds, respectively, to the molecular weights of different molecular weight species contained in a polymer, the weight-average to number-average molecular weight ratio M _w/M _n cannot exceed (1 + M_max/M_min)²/(4M_max/M_min). The ratio attains this maximum possible value if the masses of the two species with molecular weights M_min and M_max are equal and the masses of all the other species are negligibly small, corresponding to maximum spread in the molecular weight distribution within the specified bounds. Also for a given value of M _w/M _n = α, the M_max cannot be smaller than [2α ? 1 + 2α^1/2(α ? 1)^1/2]M_min. The minimum possible value of M_max/M_min consistent with α given is obtained in the case of maximum spread described above. If only one species is predominant, then both M _w/M _n and M_max/M_min approach unity, as is well known. Similar relations hold for the ratios of higher-order average molecular weights for which the role of the mass fractions is replaced by higher-order distribution functions.     

Effect of polycondensation methods on molecular weight distribution of nylon 610

Polycondensation methods greatly influence the molecular weight distribution of poly(hexamethylene sebacamide) (nylon 610) as determined by gel permeation chromatography (GPC). The ratio of weight average molecular weight to number average molecular weight (M_w/M_n) was used as a measure for estimating the molecular weight distribution. The M_w/M_n ratios of nylon 610 obtained from melt, solid phase, and high temperature polycondensation methods were 2 to 3.5, which were expected values for the most probable distribution. However, those for polymers obtained from the direct polycondensation in the presence of triphenylphosphine, interfacial polycondensation and low temperature polycondensation using an acid chloride varied over a wide range from 3.5 to 8.5. The effect of the kind of organic solvents in the interfacial method on the M_w/M_n ratios was especially large, and the molecular weight distribution could be controlled to some extent by selecting an appropriate solvent.     

Influences of molecular weight and crystalline structure on fracture behavior of controlled-rheology-polypropylene prepared by reactive extrusion

The molecular weight of ethylene-block-co-polypropylene (co-PP) was adjusted by reactive extrusion with the incorporation of dicumyl peroxide (DCP), and the effect of molecular weight on the crystallization behavior, crystal morphology, and fracture behavior was investigated. It was found that, with increasing DCP content, the molecular weight (MW) decreased and the polydispersity (M_w/M_n) slightly decreased. After modification, the number of spherulites with obscure boundaries increased, and the size of the spherulites was more even due to increasing amount of grafting and micro-cross-linking structures, generated in co-PP degradation, which were acting as nucleating agents. Evaluated by essential work of fracture method, the specific essential work of fracture, w_e, was found to be strongly dependent on the molecular weight, especially, on the number average molecular weight (M_n) linearly, while the specific non-essential work of fracture, βw_p, was enhanced with decreasing z-average molecular weight (M_z), probably owing to the reduction of ultra-high molecular weight component in degraded co-PP.     

Interfacial tension between low molecular weight polymers from the static analysis of cylindrical drops and their break-up dynamics

A spinning drop tensiometer was used to measure the interfacial tension between the coexisting phases of mixtures of low molecular weight polypropylene glycol, M_w = 1000, and polyethylene glycol, M_w = 300, 400, or 550. Two types of experiments gave concordant interfacial tensions. First, the static analysis of the equilibrium diameter of cylindrical drops according to Vonnegut and, second, Tomotika's dynamic analysis of Rayleigh instabilities caused by a sharp decrease of the angular speed. The end-pinching process also lead to the break-up of the drops and it was characterized by a rapid expansion of the hemispherical ends followed by a slower pinching step. The pinching rate increases as the final angular speed decreases while the growth rate of Rayleigh instabilities shows no definite trends in the range 118-245 rad · s^?1. It is shown that the end-pinching of long cylindrical drops can be analyzed in terms of short fiber retraction to get the interfacial tension. © 1995 John Wiley & Sons, Inc.     

Molecular weight characterization of soluble high performance polyimides. 2. Validity of universal SEC calibration and absolute molecular weight calculation

Six different soluble high-performance aromatic polyimides, each prepared by solution imidization to three controlled average molecular weights, were analyzed by size exclusion chromatography (SEC) using on-line parallel coupled refractometric and viscometric detectors. N-methylpyrrolidone (NMP) with 0.06 M LiBr and NMP stirred over P₂O₅ were used as mobile phase for four of the polyimides; NMP with 0.06 M LiBr and NMP stirred over P₂O₅ were used as mobile phases for four of the polyimides; NMP with 0.06 M LiBr tetrahydrofuran (THF) and chloroform served as mobile phases for the other two polyimides. For all the samples the stationary phase in the SEC columns was cross-linked polystyrene beads. Molecular weight averages of the polyimides were calculated using universal SEC calibration with polystyrene standards in each solvent. The agreement of the calculated molecular weight averages in the different solvents confirms that the universal SEC calibrations are valid for these semiflexible polymers. There was good agreement with weightaverage molecular weights obtained by low-angle laser light scattering (LALLS) performed in pure NMP. Intrinsic viscosity and molecular weight data for a series of nine samples of one polyimide covering a M_w = 20,000–70,000 g mol^–1 interval were treated to obtain Mark-Houwink-Sakurada constants. Unperturbed chain dimensions of this polyimide were obtained by application of the Stockmayer-Fixman extrapolation procedure to these data. ©1995 John Wiley & Sons, Inc.     

Synthesis of high molecular weight polystyrene using AGET ATRP under high pressure

High molecular weight polystyrene (PS) was synthesized by ATRP. Under atmospheric pressure (1 bar), PS with M_n up to 200,000 was prepared using either ARGET or ICAR ATRP. Under high pressure (6 kbar), higher molecular weight PS could be obtained due to accelerated radical propagation and diminished radical termination in polymerization of styrene. Therefore, it was possible to synthesize PS with M_n > 1,000,000 and M_w/M_n < 1.25 using AGET ATRP under a pressure of 6 kbar at room temperature. This is the highest molecular weight linear PS prepared by a controlled radical polymerization.     

Coextrusion drawing of reactor powder of ultrahigh molecular weight polyethylene

Certain nascent polymers have been shown to have unusual thermal and morphological properties that are irretrievably lost once the polymer has been melted or otherwise reduced to the isotropic state. We show further that nascent ultrahigh molecular weight polyethylene “reactor powder” exhibits a remarkable ductility when uniaxially drawn by coextrusion techniques after initial compaction in film form at 100°C. When drawn at a temperature of 110°C, draw ratios of 56 have been obtained, resulting in an enhanced tensile modulus of 58 GPa. Thermal analyses and dynamic mechanical measurements were also made towards understanding the initial and final morphologies.     

Influence of extrusion ratio on the thermal properties and morphology of ultradrawn high-density polyethylene

Solid-state extrusion of high-density polyethylene (HDPE) has received considerable attention. It has been shown that extrudate may have high values of optical clarity, tensile modulus (～70 GPa = 7 × 10¹¹ dyn/cm²), and c-axis orientation. The effects of extrusion conditions on the properties of the resultant fibers have, however, not yet been clarified. A systematic study has thus been made here to evaluate extrusion pressure, temperature, and extrusion (draw) ratio, and the molecular weight of extruded HDPE. The effects of extrusion ratio on the degree of crystallinity, melting behavior, crystal orientation, and dimensional change along the extrusion direction are reported.     

Pecularities of the thermomechanical behaviour of ultra-high molecular weight linear polyethylene and its blends with linear polyethylene of normal molecular weight

Ultra-high molecular weight polyethylene UHMWPE (M _w=4 · 10⁶,I _s=O g/ 10 min), high density polyethylene of normal molecular weight NMWPE (I _s= 4.8 g/10 min) and their blends have been investigated by means of thermomechanical loading in constant and impulse regime. It has been established that after melting, NMWPE passes to a viscous-liquid state. After melting at 138 °C UHMWPE passes to a high-elastic state. The transition of UHMWPE to a viscous-liquid state takes place at temperatures higher than 180 °C and is accompanied by a high-elastic reversible deformation. The blends of UHMWPE with 10 and 20 mass % of NMWPE show a plateau on the thermomechanical curves, corresponding to a high-elastic state, in a shorter temperature range where the deformation is greater. The blends containing the higher percent of NMWPE show thermomechanical curves lacking such a plateau. All blends are characterized by a singular thermomechanically defined temperature of melting, which increases with increase of UHMWPE content. The existence of the high-elastic state in the curves of UHMWPE and its blends containing NMWPE less than 30 mass % above their melting temperatures is explained by the high degree of physical crosslinking of UHMWPE.     

Molecular weight distribution and mechanical behavior of PBI fibers

Two different polybenzimidazole (PBI) samples have been investigated in order to correlate the differences in molecular weight distribution (MWD) with changes in the elastic modulus and strength of undrawn and drawn fibers. It has been found that within the weight-average molecular weight range (7,000 ≤ M_w ≤ 13,000) there was no obvious correlation with M_w and M_n. However, one sample had a narrow unimodal molecular weight distribution and the other a wide bimodal molecular weight distribution. The small percentage of high molecular weight present in the latter sample gave its fibers better mechanical properties. X-ray diffraction studies showed that the orientation in both drawn fiber samples was equal. This isolated the effects of the molecular weight distribution on mechanical properties.     

Control of the molecular weight of hyperbranched polyglycerols

Hyperbranched polyglycerols exceeding M_n > 15,000 g/mol (DP_n > 270) have been prepared, using a modified version of the synthetic protocol reported earlier. In the optimized process polydispersities recorded by SEC remained narrow, with M_w/M_n < 1.7 over a large molecular weight range. The drastic increase of viscositity in the course of the reaction, was found to be responsible for the increased fraction of cycles (MALDI‐TOF MS) at high molecular weights.