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.     

Polymeric micro‐sequential concentric transcrystalline morphology self‐assembly,with intermittent self‐shear‐oriented amorphous layers

The investigation and understanding of polymer crystallization processes, the resulting crystalline morphologies, and the mechanism of their formation is crucial in creating materials with desired properties for specific applications. The present research introduces and investigates a new polymeric crystalline morphology, observed for the first time in this research. This newly observed morphology, is a sequentially micro‐multi‐layered concentric morphology that self‐assembles throughout the bulk polymer matrix, with intermittent self‐shear‐oriented amorphous layers. The research analyses the structure and mechanism of its formation. Polarized light microscopy studies have shown a drastic and sudden morphology change that occurred during crystalline growth. Crystalline‐growth kinetics studies performed, showed a distinct pulsatile repeating growth pattern of approximately two growth pulses per second. Thermal analysis indicated the presence of two different populations of crystalline strength. Crystalline structure was analyzed by XRD pattern measurements. It was demonstrated here, that the sequential concentric transcrystalline morphology is nucleated on a shear‐oriented amorphous molecular layer in the adjacent melt formed during and as a consequence of crystalline growth, which occurs in a micro‐periodic sequences, with intermittent self‐sheared amorphous layers. The structure was confirmed by both scanning electron microscope and reflectance microscopy. Small angle X‐ray scattering measurements of the same materials reported in literature are consistent with the melt shear‐orientation theory described earlier. The discovery of this new crystalline morphology in this research, potentially opens a new door in the vast field of material properties and applications. Copyright © 2017 John Wiley & Sons, Ltd.     

Role of dicumyl peroxide on the morphology and mechanical performance of polypropylene random copolymer in microinjection molding

The purpose of this work is to systematically investigate the effects of dicumyl peroxide (DCP) on the microstructural evolution and mechanical properties of polypropylene random copolymers (PPRs) during the microinjection process. Polarized light microscopy, differential scanning calorimetry, X‐ray diffraction, and scanning electronic microscopy measurements were employed to characterize the morphology evolution of the PPR microparts with DCP. A hierarchical structure was found in the PPR microparts with DCP. Specifically, with the individual addition of organic peroxide, the orientation parameter of the PPR microparts decreased pronouncedly and the formation of skin layer was suppressed, while the formation of core layer was promoted. This was ascribed to the distribution of shear rate in the microchannel, which was determined by the wall ship effect in the filling stage and the relaxation behavior in the cooling stage. A mechanism was proposed to explain the distinctive filling behavior and molding characteristics of PPR with DCP in microinjection molding.     

Melt‐extensional properties and orientation behaviors of polypropylene‐layered silicate nanocomposites

Polypropylene‐layered silicate nanocomposites consisting of three components—pure polypropylene, maleated polypropylene, and organically modified silicate—were prepared by the melt‐intercalation method to investigate melt‐extensional properties such as melt strength, neck‐in test, and orientation behavior. The nanocomposites showed an enhanced tensile modulus, enhanced storage modulus, much enhanced melt tension, and reduced neck‐in during the melt processing as compared with neat polymer. The uniaxial drawing induced the silicate surface to align parallel to the sheet surface. The c and a* axes of the polypropylene crystals were bimodally oriented to the flow direction, and the b axes were oriented to the thickness direction. The bimodal orientation of the polypropylene crystal was enhanced with the concentration of silicates. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 158–167, 2005     

(110)‐Oriented ZIF‐8 Thin Films on ITO with Controllable Thickness

(110)‐oriented zeolitic imidazolate framework (ZIF)‐8 thin films with controllable thickness are successfully deposited on indium tin oxide (ITO) electrodes at room temperature. The method applied uses 3‐aminopropyltriethoxysilane (APTES) in the form of self‐assembled monolayers (SAMs), followed by a subsequent adoption of the layer‐by‐layer (LBL) method. The crystallographic preferential orientation (CPO) index shows that the ZIF‐8 thin films are (110)‐oriented. A possible mechanism for the growth of the (110)‐oriented ZIF‐8 thin films on 3‐aminopropyltriethoxysilane modified ITO is proposed. The observed cross‐sectional scanning electron microscopy (SEM) images and photoluminescent (PL) spectra of the ZIF‐8 thin films indicate that the thickness of the ZIF‐8 layers is proportional to the number of growth cycles. The extension of such a SAM method for the fabrication of ZIF‐8 thin films as described herein should be applicable in other ZIF materials, and the as‐prepared ZIF‐8 thin films on ITO may be explored for photoelectrochemical applications.     

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.     

Structural and morphological studies on the deformation behavior of polypropylene/multi‐walled carbon nanotubes nanocomposites prepared through ultrasound‐assisted melt extrusion process

Structural and morphological behavior under stress–strain of polypropylene/multi‐walled carbon nanotubes (PP/MWCNTs) nanocomposites prepared through ultrasound‐assisted melt extrusion process was studied by means of optical microscopy, scanning electron microscopy, transmission electron microscopy, Raman spectroscopy, small angle X‐ray scattering (SAXS), and wide angle X‐ray scattering (WAXS). A high ductile behavior was observed in the PP/MWCNT nanocomposites with low concentration of MWCNTs. This was related to an energy‐dissipating mechanism, achieved by the formation of an ordered PP‐CNTs interphase zone and crystal oriented structure in the undeformed samples. Different strain‐induced‐phase transformations were observed by ex situ SAXS/WAXS, characterizing the different stages of structure development during the deformation of PP and PP/MWCNTs nanocomposites. The high concentration of CNTs reduced the strain behavior of PP due to the agglomeration of nanoparticles. A structural pathway relating the deformation‐induced phase transitions and the dissipation energy mechanism in the PP/MWCNTs nanocomposites at low concentration of nanoparticles was proposed. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 475–491     

Epitaxy‐like orientation of nanoscale Ag islands grown on air‐oxidized Si(110)‐(5 × 1) surfaces

Growth of Ag islands under ultra‐high vacuum condition on air‐oxidized Si(110)‐(5 × 1) surfaces has been investigated by in situ reflection high energy electron diffraction and ex situ scanning electron microscopy and cross‐sectional transmission electron microscopy. A thin oxide is formed on Si via exposure of the clean Si(110)‐(5 × 1) surface to air. The oxide layer has a short range order. Deposition of Ag at different thicknesses and at different substrate temperatures reveal that the crystalline qualities of the Ag film are almost independent of the thickness of the Ag layer and depend only on the substrate temperature. Ag deposition at room temperature leads to the growth of randomly oriented Ag islands while preferred orientation evolves when Ag is deposited at higher temperatures. For deposition at 550 °C sharp spots in the reflection high energy electron diffraction pattern corresponding to an epitaxial orientation with the underlying Si substrate are observed. The presence of a short range order on the oxidized surface apparently influences the crystallographic orientation of the Ag islands. Copyright © 2011 John Wiley & Sons, Ltd.     

Controlled sub‐10‐nanometer poly(N‐isopropyl‐acrylamide) layers grafted from silicon by atom transfer radical polymerization

Surface‐initiated atom transfer radical polymerization (SI‐ATRP) was used to graft poly(N‐isopropylacrylamide) (PNIPAM) brush layers with a controllable thickness in the 10‐nm range from silicon substrates. The rate of polymerization of N‐isopropylacrylamide was tuned by the [Cu(II)]₀/[Cu(I)]₀ ratio between the deactivating and activating species. The polymer layer thickness was characterized by atomic force microscopy (AFM) and ellipsometry. PNIPAM layers with a dry thickness between 5.5 and 16 nm were obtained. Time‐of‐flight secondary ion mass spectrometry (ToF‐SIMS) confirmed that the chemical structure is PNIPAM brushes. Analysis of the AFM data showed that our procedure leads to polymer grafts in the “mushroom‐to‐brush” transition regime.     

Molecular orientation of a ZnS‐nanocrystal‐modified M13 virus on a silicon substrate

The surface structure and cast film formation process of a ZnS‐nanocrystal‐modified M13 bacteriophage (ZnS–M13) were investigated. A ZnS–M13 film oriented under the influence of a capillary force was obtained on both single‐crystal and polycrystalline substrates. The film formation process was investigated with atomic force microscopy and scanning electron microscopy. The surface images showed that the degree of orientation of the molecular long axes greatly depended on the direction of force and the concentration of aqueous solutions. Controlling the aqueous solution concentration yielded a highly oriented ZnS–M13 film on an indium tin oxide plate. The ability to control the orientation of virus‐based films may lead to new types of hybrid materials in which the components are organized on several length scales. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 629–635, 2004     

Orientation‐Controlled Single‐Molecule Junctions

The conductivity of a single aromatic ring, perpendicular to its plane, is determined using a new strategy under ambient conditions and at room temperature by a combination of molecular assembly, scanning tunneling microscopy (STM) imaging, and STM break junction (STM‐BJ) techniques. The construction of such molecular junctions exploits the formation of highly ordered structures of flat‐oriented mesitylene molecules on Au(111) to enable direct tip/π contacts, a result that is not possible by conventional methods. The measured conductance of Au/π/Au junction is about 0.1 G_o , two orders of magnitude higher than the conductance of phenyl rings connected to the electrodes by standard anchoring groups. Our experiments suggest that long‐range ordered structures, which hold the aromatic ring in place and parallel to the surface, are essential to increase probability of the formation of orientation‐controlled molecular junctions.     

Predicting the location of weld line in microinjection‐molded polyethylene via molecular orientation distribution

The microstructure and molecular orientation distribution over both the length and the thickness of microinjection‐molded linear low‐density polyethylene with a weld line were characterized as a function of processing parameters using small‐angle X‐ray scattering and wide‐angle X‐ray diffraction techniques. The weld line was introduced via recombination of two separated melt streams with an angle of 180° to each other in injection molding. The lamellar structure was found to be related to the mold temperature strongly but the injection velocity and the melt temperature slightly. Furthermore, the distributions of molecular orientation at different molding conditions and different positions in the cross section of molded samples were derived from Hermans equation. The degree of orientation of polymeric chains and the thickness of oriented layers decrease considerably with an increase of both mold temperature and melt temperature, which could be explained by the stress relaxation of sheared chains and the reduced melt viscosity, respectively. The level of molecular orientation was found to be lowest in the weld line when varying injection velocity, mold temperature, and melt temperature, thus providing an effective means to identify the position of weld line induced by flow obstacles during injection‐molding process. © 2019 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2019 , 57, 1705–1715     

Unexpected Intermediate State for the Cylinder‐to‐Gyroid Transition in a Block Copolymer Solution

The cylinder‐to‐gyroid transition in a concentrated solution of polystyrene‐block‐polyisoprene in dibutyl phthalate has been studied using rheology and small angle X‐ray scattering. Following an appropriate temperature quench, the oriented cylinder phase transforms to the gyroid structure epitaxially. Remarkably, an intermediate state appears for a deep quench, whereas for a shallow quench the transition proceeds directly; the intermediate state exhibits scattering signatures consistent with a hexagonally perforated layer structure.     

Morphology and Linear Viscoelasticity of Poly[ethylene‐co‐(1‐octene)]/Layered Silicate Nanocomposites

Poly[ethylene‐co‐(1‐octene)] nanocomposites with different microstructures were prepared with two kinds of organoclay by melt intercalation. X‐ray diffraction and transmission electron microscopy were used to characterize the morphology of the composites. Linear storage moduli of the composites in the melt state were found to increase greatly with increasing the extent of dispersion of silicate layers and showed an obvious sensitivity to the morphologies of the composites.     

Surface Modification by Compositionally Modulated Multilayered Zn‐Fe Alloy Coatings

Compositionally modulated multilayered alloy (CMMA) coatings of Zn-Fe were developed from acid chloride baths by single bath technique. The production and properties of CMMA Zn-Fe coatings were tailored as a function of switching cathode current densities (SCCD’s) and thickness of individual layers. Corrosion rates (CR) were measured by electrochemical methods. Corrosion resistances were found to vary with SCCD’s and the number of sub layers in the deposit. SCCD’s were optimized for production of Zn-Fe CMMA electroplates showing peak performance against corrosion. The formation of discrete Zn-Fe alloy layers having different compositions in the deposits were demonstrated by scanning electron microscopy (SEM). Improvements in the corrosion resistance of multilayered alloys are due to the inherent barrier properties of CMMA coatings as evidenced by electrochemical impedance spectroscopy (EIS). Corrosion resistance afforded by Zn-Fe CMMA coatings are explained in terms of the n-type semiconductor films at the interface, supported by Mott-Schottky’s plot. It was observed that the alloy with high w(Fe) on the top showed better corrosion resistance compared to that with the less w(Fe) on top. At optimum SCCD’s of 3.0—5.5 A•dm－2, a Zn-Fe CMMA coatings with 600 sub layers showed ca. 45 times better corrosion resistance than conventional Zn-Fe alloy of the same thickness. The deposit showed no red rust even up to 1130 h in salt spray test.     

A novel hierarchical crystalline structure of injection-molded bars of linear polymer: co-existence of bending and normal shish–kebab structure

The hierarchy structures and orientation behavior of high-density polyethylene (HDPE) molded by conventional injection molding (CIM) and gas-assisted injection molding (GAIM) were intensively examined by using scanning electronic microscopy (SEM) and 2D wide-angle X-ray diffraction (2D-WAXD). Results show that the spatial variation of crystals across the thickness of sample molded by CIM was characterized by a typical skin–core structure as a result of general shear-induced crystallization. Unusually, the crystalline morphologies of the parts prepared by GAIM, primarily due to the penetration of secondary high-compressed gas that was exerted on the polymer melt during gas injection, featured a richer and fascinating supermolecular structure. Besides, the oriented lamellar structure, general shish–kebab structure, and common spherulites existed in the skin, sub-skin, and gas channel region, respectively; a novel morphology of shish–kebab structure was seen in the sub-skin layer of the GAIM parts of HDPE. This special shish–kebab structure (recognized as “bending shish–kebab”) was neither parallel nor perpendicular to the flow direction but at an angle. Furthermore, there was a clear interface between the bending and the normal shish–kebab structures, which may be very significant for our understanding of the melt flow or polymer rheology under the coupling effect of multi-fluid flow and complex temperature profiles in the GAIM process. Based on experimental observations, a schematic illustration was proposed to interpret the formation mechanism of the bending shish–kebab structure during GAIM process.     

Structural transformation from shish‐kebab crystals to micro‐fibrils through hot stretching process of gel‐spun ultra‐high molecular weight polyethylene fibers with high concentration solution

Structural evolution of gel‐spun ultra‐high molecular weight polyethylene fibers with high concentration solution via hot stretching process was investigated by in situ small‐angle X‐ray scattering, in situ wide‐angle X‐ray diffraction measurements, scanning electron microscopy, and differential scanning calorimetry. With the increase of stretching strain, the long period continuously increases at relative lower stretching temperature, while it first increases and then decreases rapidly at relative higher stretching temperature. The kebab thickness almost keeps constant during the whole hot‐stretching process and the kebab diameter continually decreases for all stretching temperatures. Moreover, the length of shish decreases slightly and the shish quantity increases although there is almost no change in the diameter of shish crystals during the hot stretching process. The degree of crystal orientation at different temperatures is as high as above 0.9 during the whole stretching process. These results indicate that the shish‐kebab crystals in ultra‐high molecular weight polyethylene fibers can transform continuously into the micro‐fibril structure composed mostly of shish crystals through the hot stretching process. © 2017 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2018 , 56, 225–238     

Poly(ethyleneimine) microcapsules: glutaraldehyde‐mediated assembly and the influence of molecular weight on their properties

Poly(ethyleneimine) (PEI) microcapsules were prepared via the method of glutaraldehyde (GA)‐mediated covalent layer‐by‐layer (LbL) assembly, which utilized GA to cross‐link the adsorbed PEI layer and to introduce free aldehyde group on the surface for the next PEI adsorption on MnCO₃ microparticles, followed by core removal. Evidenced by ellipsometry, the PEI multilayers grew nearly linearly along with the layer number and their thickness was controlled at the nanometer scale. The hollow structure, morphology, and wall thickness were characterized by scanning electron microscopy (SEM), scanning force microscopy (SFM), and confocal laser scanning microscopy (CLSM), revealing that the capsule structure as well as the cut‐off molecular weight of the capsule wall could be tuned by the molecular weight of PEI. This offers a general and novel pathway to fabricate single component capsules with pre‐designed structure (size, shape, and wall thickness) and properties. Copyright © 2007 John Wiley & Sons, Ltd.     

Poly(L‐lactide)/layered double hydroxides nanocomposites: Preparation and crystallization behavior

Novel nanocomposites from poly(L ‐lactide) (PLLA) and an organically modified layered double hydroxide (LDH) were prepared using the melt‐mixing technique. The structure and crystallization behavior of these nanocomposites were investigated by means of wide‐angle X‐ray diffraction (WAXD), transmission electron microscopy (TEM), Fourier transform infrared (FTIR) spectroscopy, differential scanning calorimetry (DSC), and polarized optical microscopy (POM). WAXD results indicate that the layer distance of dodecyl sulfate‐modified LDH (LDH‐DS) is increased in the PLLA/LDH composites, compared with the organically modified LDH. TEM analysis suggests that the most LDH‐DS layers disperse homogenously in the PLLA matrix in the nanometer scale with the intercalated or exfoliated structures. It was found that the incorporation of LDH‐DS has little or no discernable effect on the crystalline structure as well as the melting behavior of PLLA. However, the crystallization rate of PLLA increases with the addition of LDH‐DS. With the incorporation of 2.5 wt % LDH‐DS, the PLLA crystallization can be finished during the cooling process at 5 °C/min. With the addition of 5 wt % LDH‐DS, the half‐times of isothermal melt‐crystallization of PLLA at 100 and 120 °C reduce to 44.4% and 57.0% of those of the neat PLLA, respectively. POM observation shows that the nucleation density increases and the spherulite size of PLLA reduces distinctly with the presence of LDH‐DS. © 2008 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 46: 2222–2233, 2008