Nucleator-Enhanced Molecular Orientation and Crystallization in Melt-Spun Monofilaments of Syndiotactic Polypropylene

Different from other semi-crystalline polymers, the crystallization of syndiotactic polypropylene (sPP) into helical sequences under flow is largely inhibited due to favorable formation of trans-planar conformations. The results presented in this study, using micro-FTIR, 2D-WAXS, and 2D-SAXS characterization, indicate that molecular orientation and crystallization in melt-spun sPP monofilaments can be dramatically enhanced by a sorbitol-based nucleator. It is suggested that, similar to the oriented crystallization in the nucleated isotactic polypropylene (iPP), the phase-separated nanofibrils, aligned under flow prior to sPP crystallization, act as shish structure (primary nuclei) to mediate the molecular orientation and crystallization of sPP.     

Influence of shear on polypropylene crystallization kinetics

Isothermal crystallization kinetics under shear in the melt of iPP was investigated by optical microscopy. It appears that shearing from 200 to the crystallization temperatures enhanced the kinetics, but the shear effect was not obvious if the melt of iPP was sheared only at 200. The experiment results show that relaxation plays an important role during crystallization, and that spherulite growth rates increased with shear rates and were governed by relaxation. The effect of flow on the crystallization kinetics can be understood by considering that the increase of the degree of order due to flow results is an effective change of the melt free energy. The Laurizen-Hoffman theory and the DE-IAA model were used to describe the shear-induced crystallization kinetics of iPP excellently.Received: 30 August 2004, Published online: 19 October 2004PACS: 61.41. + e Polymers, elastomers, and plastics - 61.50.-f Crystalline state - 64.70.-p Specific phase transitions     

CO2-induced Crystallization of Isotactic Polypropylene by Annealing Near Its Melting Temperature

CO₂-induced crystallization of isotactic polypropylene (iPP) by annealing had been studied using differential scanning calorimetry (DSC), wide-angle X-ray diffraction (WAXD) and small-angle X-ray scattering (SAXS). The iPP before annealed was in α-form and amorphous states. At lower temperatures by CO₂ isothermal treatments, iPP chains crystallized from the amorphous phase and only one crystal form, i.e., α-form, was observed. At higher temperatures by CO₂ isothermal treatments, both crystallization from the amorphous phase and thickening of existing crystal lamellae were observed. Moreover, light γ-form crystal appeared in the treated iPP. The crystalline lamellar thickness of iPP annealed at different CO₂ pressures had been determined. Using the Gibbs–Thomson plot method, the equilibrium melting temperature was found to be 187.6°C.     

Isothermal Crystallization and Miscibility of Isotactic Polypropylene/Poly(cis-butadiene) Rubber Blends

Isotactic polypropylene/poly(cis-butadiene) rubber (iPP/PcBR) blends were prepared by melt mixing. Isothermal crystallization and miscibility for neat iPP and blends of iPP/PcBR were investigated by differential scanning calorimetry. The presence of PcBR remarkably affected isothermal crystalline behaviors of iPP. An addition of PcBR caused shorter crystallization time and a faster overall crystallization rate, meaning a heterogeneous nucleation effect of PcBR upon crystallization of iPP. For the same sample, the crystallization peak was broader and the supercooling decreased as the crystallization temperature increased. The Avrami equation was suitable to describe the primary isothermal crystallization process of iPP and blends. The addition of PcBR led to an increase of values of the Avrami exponent n, which we suggest was because the blends had a stronger trend of instantaneous three-dimensional growth than neat iPP. The equilibrium melting point depression of the blends was observed, indicating that the blends were partly miscible in the melt.     

The Role of Poly(phenylene sulfide) Microfibrils in Isothermal Crystallization of Isotactic Polypropylene under Shear

An optical polarizing microscope with a hot shear stage was used for an in‐situ investigation of the influences of poly(phenylene sulfide) (PPS) microfibrils on isothermal crystallization of isotactic polypropylene (iPP) under shear. As the nucleation sites on the PPS microfibril's surface are not able to induce a transcrystalline layer, there are only spherulites generated in a PPS/iPP in‐situ microfirbillar blend in quiescent condition. Applying shear during isothermal crystallization, the crystalline morphology greatly changes. There are fibrillar nuclei induced after steady shear with a shear rate of 5 and 10 s^–1, and these nuclei formed fibrillar crystals after crystallization completion. Two opposite effects coexist in PPS/iPP in‐situ microfibrillar blends during shear‐induced isothermal crystallization; one is the obstructive effect of PPS microfibrils on the iPP molecular chains orientation; the other is the positive effect provided by stress between fiber and matrix, generated by shear, which reduces the potential barrier of crystallization. The results of wide angle x‐ray diffraction (WAXD) show that there are β‐iPP crystals generated in neat iPP and PPS/iPP blends, but that PPS microfibrils have an inhibiting influence on the formation of β‐iPP.     

Micro and Macro Injection Molded Parts of Isotactic Polypropylene/Polyethylene Blends: Shear-Induced Crystallization Behaviors and Morphological Characteristics

The present study focused on the importance of scale effect (micro- and macro-injection molded parts) and iPP content to the formation of epitaxial crystallization and crystal structure formed in injection-molded bars of high-density polyethylene (HDPE)/isotactic polypropylene (iPP) blends. After making the blends with different iPP content via melt mixing, the injection-molded bars were prepared via both micro and conventional injection molding. Hot stage polarized light microscopy (HS-PLM), scanning electron microscopy (SEM), differential scanning calorimetry (DSC) and wide-angle X-ray diffraction (WAXD) were used to investigate their morphological and crystal features. The results indicated that an appropriate matching of micro-part and relative high iPP content was most favorable for epitaxial crystallization. The micro-parts had a large fraction of shear layer in comparison with macro-parts. The SEM observations showed that the shear layer of the former consisted of a highly oriented shish-kebab structure. The memory effect of the crystalline structure of the micro-parts and macro-parts at high temperature, investigated in detail through HS-PLM experiments, showed that micro-part had a relatively high memory effect of the preceding crystallization process.     

Crystallization Kinetics of Nucleated Polypropylene with Organic Phosphates

The crystallization kinetics of isotactic polypropylene (iPP) and nucleated iPP with two organic phosphates, sodium salt (NA7) and triglyceride ester (NA8) of 2,2'-methylene-bis(4,6-di-tert-butylphenyl) phosphoric acid, were investigated by means of a differential scanning calorimeter under isothermal and nonisothermal conditions. During isothermal crystallization, a modified Avrami equation was used to describe the crystallization kinetics. Moreover, kinetics parameters, such as the Avrami exponent, n, the crystallization rate constant, k, and the half-time of crystallization, τ_1/2, are compared. The results showed that a dramatic decrease of the half-time of crystallization, as well as a significant increase of the overall crystallization rate, were observed in the presence of the organic phosphates. During nonisothermal crystallization, the primary crystallization was analyzed using the Ozawa model, leading to similar Avrami exponents for iPP and iPP/NA7, which means simultaneous nucleation with three-dimensional spherulitic growth. However, for iPP/NA8, the Avrami exponent in nonisothermal crystallization is evidently different from that in isothermal crystallization, which would indicate a different mechanism of crystal growth. Adding the nucleating agent to iPP makes the overall crystallization activation energy increase.     

Formation of β-iPP in Isotactic Polypropylene/Acrylonitrile–Butadiene–Styrene Blends: Effect of Resin Type,Phase Composition,and Thermal Condition

The formation of β-iPP (β-modification of isotactic polypropylene) in the iPP/ABS (acrylonitrile–butadiene–styrene), iPP/styrene–butadiene (K resin), and iPP/styrene–acrylonitrile (SAN) blends were studied using differential scanning calorimery (DSC), wide angle X-ray diffraction (WAXD), and scanning electron microscopy (SEM). It was found that α-iPP (α-modification of isotactic polypropylene) and β-iPP can simultaneously form in the iPP/ABS blend, whereas only α-iPP exists in the iPP/K resin and iPP/SAN blend samples. The effects of phase composition and thermal conditions on the β-iPP formation in the iPP/ABS blends were also investigated. The results showed that when the ABS content was low, the ABS dispersed phase distributed in the iPP continuous phase, facilitating the growth of β-iPP, and the maximum amount of β-iPP occurred when the composition of iPP/ABS blend approached 80:20 by weight. Furthermore, it was found that the iPP/ABS blend showed an upper critical temperature T _c * at 130°C for the formation of β-iPP. When the crystallization temperature was higher than the T _c *, the β-iPP did not form. Interestingly, the iPP/ABS blend did not demonstrate the lower critical temperature T _c ** previously reported for pure iPP and its blends. Even if the crystallization temperature decreased to 90°C, there was still β-iPP generation, indicating that ABS has a strong ability to induce the β-iPP. However, the annealing experiments results revealed that annealing in the melt state could eliminate the susceptibility to β-crystallization of iPP.     

Induction time as a measure for heterogeneous spherulite nucleation: Quantitative evaluation of early-stage growth kinetics

A theory is proposed indicating that the induction time characterizes the nucleation process in polymer crystallization. A microscopic method has been developed to monitor early stages of the spherulite growth. Using the method, based on photometric measurement of the depolarized light intensity during isothermal crystallization from the melt, nonzero nucleation induction time values were found for polypropylene (PP). From comparison of the theory with the experimental results obtained from polypropylene crystallization, it follows that the formation of PP crystal nuclei on admixtures is affected both by the formation of the first crystalline layer and by the size of the critical nucleus.     

Polypropylene Nanocomposites Based on Synthetic Organic-Soluble Ag Nanocrystals with Prominent β-nucleating Effect: Quiescent Crystallization and Melting Behavior

Differential scanning calorimetry, x-ray diffraction, and polarized optical microscopy were used to investigate the quiescent crystallization and melting behavior of isotactic polypropylene (iPP) nanocomposites based on synthetic organic-soluble Ag nanocrystals (NCs). The effects of Ag loading and crystallization temperature on the crystallization behavior and crystalline structure were studied. The results showed that the synthetic Ag NCs as a novel effective β-crystal nucleating agent for iPP could promote the overall crystallinity, decrease the size of spherulites, and induce the formation of large amounts of β-crystals in the nanocomposites under quiescent crystallization. The relative content of β-crystals significantly increased with increasing Ag loading, and slightly increased with decreasing crystallization temperature. The quiescent crystallization kinetics was analyzed using the Avrami model. The results showed that the iPP nanocomposites with added Ag NCs had higher crystallization rate constant (k) and lower crystallization half-times (t_1/2) as well as the Avrami exponent (n) than pure iPP, indicating that the presence of Ag NCs acted as heterogeneous nucleating sites and promoted the crystallization rate of iPP.     

Nonisothermal Crystallization Nucleation of In‐Situ Fibrillar and Spherical Inclusions in Poly (Phenylene Sulfide)/Isotactic Polypropylene Blends

Nonisothermal crystallization nucleation and its kinetics of in‐situ fibrillar and spherical dispersed phases in poly (phenylene sulfide) (PPS)/isotactic polypropylene (iPP) blends are discussed. The PPS/iPP in‐situ microfibrillar reinforced blend (MRB) was obtained via a slit‐die extrusion, hot stretching, and quenching process, while PPS/iPP common blend with spherical PPS particles was prepared by extrusion without hot stretching. Morphological observation indicated that the well‐defined PPS microfibrils were in situ generated. The diameter of most microfibrils was surprisingly larger than or equal to the spherical particles in the common blend (15/85 PPS/iPP by weight). The nonisothermal crystallization kinetics of three samples (microfibrillar, common blends, and neat iPP) were investigated with differential scanning calorimetry (DSC). The PPS microfibrils and spherical particles could both act as heterogeneous nucleating agents during the nonisothermal crystallization, thus increasing the onset and maximum crystallization temperature of iPP, but the effect of PPS spherical particles was more evident. For the same material, crystallization peaks became wider and shifted to lower temperature when the cooling rate increased. Applying the theories proposed by Ozawa and Jeziorny to analyze the crystallization kinetics of neat iPP, and microfibrillar and common PPS/iPP blends, both of them could agree with the experimental results.     

Isothermal Crystallization of Isotactic Polypropylene Nucleated with a Novel Aromatic Heterocyclic Phosphate Nucleating Agent

The incorporation of a nucleating agent into isotactic polypropylene (iPP) is one of the most important and widely used methods to improve performance in the polypropylene industry. Aromatic heterocyclic phosphate salt is a kind of highly effective nucleating agent for iPP and one of the typical products is a compound nucleating agent based on 2, 2-methylene-bis (4, 6-di-tert-butylphenyl) phosphate hydroxyl aluminum (commercial product name: ADK NA-21). In this paper the isothermal crystallization kinetics of iPP nucleated with the α-nucleating agent NA-21, investigated using differential scanning calorimetry (DSC), is described with the crystallization data being analyzed by using the classic Avrami method. During isothermal crystallization the addition of nucleating agent NA-21 dramatically shortened the crystallization half time (t_1/2) of iPP under the same conditions and the crystallization activation energy, ΔE, decreased from 422 kJ/mol for virgin iPP to 369 kJ/mol with the addition of NA-21. Thus, the addition of NA-21 significantly increased the crystallization rate of iPP.     

Crystalline Morphology and Nonisothermal Crystallization Behaviors of iPP/PcBR Blends

Isotactic polypropylene/poly(cis‐butadiene) rubber (iPP/PcBR) blends were prepared by melt mixing. The influence of PcBR content on crystalline morphology and nonisothermal crystallization behaviors of iPP was investigated by polarized optical microscopy (POM), small angle light scattering (SALS), and differential scanning calorimetry (DSC). The POM showed that an increase of PcBR ranging from 10 vol% to 40 vol% led to less perfection of spherulites, vaguer boundaries between spherulites, and smaller spherulite size, which was quantitatively validated by SALS. The presence of PcBR also remarkably affected the nonisothermal crystallization behaviors of iPP. An addition of PcBR caused higher crystallization peak temperature and a faster crystallization rate, meaning a heterogeneous nucleation effect of PcBR upon crystallization of iPP. For the same sample, the crystallization peak temperature moved to lower temperature and the crystallization rate increased as the cooling rate increased. The Ozawa and combined Avrami and Ozawa equations were used to describe the nonisothermal crystallization process of iPP and blends. The combined Avrami and Ozawa equation was more appropriate for the crystallization of the blends. Crystallization activation energy of iPP and blends was calculated by the Kissinger equation; the result showed that crystallization activation energy decreased as the content of PcBR increased from 30 vol% to 40 vol%.     

Investigation of the Melt‐Crystallization of Polypropylene by a Temperature Slope Method

Abstract

To investigate the in‐situ ordering process of isotactic polypropylene (iPP) from a melt state, a stationary growth front was prepared by the temperature slope crystallization (TSC) method. During the melt‐crystallization, iPP was crystallized into the α‐phase or β‐phase depending on the crystallizing conditions. The mechanism of the melt‐crystallization at the growth front was precisely observed by wide‐angle and small‐angle x‐ray scattering (WAXS and SAXS) using a strong synchrotron beam. In the TSC apparatus, the sample was crystallized in between a heater, controlled to 220°C, and a cooler, cooled by water to 25°C. We define the z‐axis parallel to the temperature gradient. A‐lamellae and B‐lamellae are also defined as those whose lamellar normal are perpendicular and parallel to the z‐axis, respectively. In a sample‐stop (SS) stage before the TSC, the original α‐phase lamellae became thicker, approaching to the melt‐solid boundary by annealing. The annealing process showed that the α‐phase B‐lamellae remained and the SAXS reflection was stronger on the meridian near the melt‐solid boundary in the SS stage. In the beginning of the TSC, the α‐phase B‐lamellae developed as a primary crystallization. During secondary crystallization under high supercooling, the SAXS cross pattern appeared showing that the α‐phase developed both A‐ and B‐lamellae. As the growth direction of A‐lamellae is parallel to the z‐axis, A‐lamellae grow faster than B‐lamellae. By the self‐epitaxial mechanism on the side surface of the A‐lamellae, the B‐lamellae grow on the base of the A‐lamellae. Following appearance of a spontaneous β‐nucleus, the β‐phase lamellae grew preferentially, excluding the α‐phase, and occupied the whole area of the sample. In this case also, A‐lamellae are advantageous to grow because of the growth direction parallel to the z‐axis. As a result, the SAXS β‐phase reflection appeared on the equator.     

Thermal Behavior of Polypropylene-g-glycidyl Methacrylate Prepared by Melt Grafting

The thermal behaviors of glycidyl methacrylate (GMA)-grafted polypropylene (PP) (PP-g-GMA) with two different grafting degrees, namely, GPP1 and GPP2, were investigated by differential scanning calorimetry (DSC), polarized optical microscopy (POM), wide-angle X-ray diffraction (WAXD), dynamic mechanical analysis (DMA), and thermogravimetrical analysis (TGA). DSC results suggested that the GMA grafted PP exhibited higher crystallization temperature T_c, higher melting temperature T_m, and higher crystallinity compared with the neat PP. The isothermal crystallization kinetics was analyzed with the Avrami equation and the total crystallization activation energy was calculated. It was concluded that the crystallization processes of PP and the grafted PP were controlled by nucleation and the values of the crystallization activation energy of PP and the grafted PP were almost identical. POM results suggested that the GMA grafted PP exhibited smaller spherulites size compared with the neat PP. WAXD patterns indicated that the neat PP encouraged the formation of γ phase, compared with the grafted PP, during the crystallization process. DMA results showed that melt grafting did not induce a clear effect on the γ-transition and β-transition of the amorphous phase but resulted in a decrease in mobility of the PP chains in the crystals. TGA curves suggested that the melt grafting slightly improved the thermal stability of PP.     

Microstructure and Mechanical Properties of Isotactic Polypropylene Films Fabricated via Melt-Extrusion and Uniaxial-Stretching

In this work, isotactic polypropylene (iPP) melt was slowly extruded through a slit die of a single-screw extruder. Once the iPP melt left the die, it was uniaxially stretched at different stretching rates (SRs). Via this process its microstructure can be manipulated, it was subsequently investigated by wide-angle X-ray diffraction (WAXD), small-angle X-ray scattering (SAXS), differential scanning calorimetry (DSC), polarized optical microscopy (POM), and Fourier transform infrared spectroscopy (FTIR). Furthermore, the mechanical properties (including tensile strength, modulus, toughness, and strain-hardening) were investigated. The results showed that the tensile strength and modulus of the melt-stretched iPP films gradually increased with increasing SRs. In addition, the toughness and elongation at break showed maximum values for iPP films melt-stretched at 30 cm/min. Moreover, compared with other melt-stretched films, the iPP films melt-stretched at 90 cm/min exhibited an obvious strain-hardening behavior at lower strain.     

Shear‐Enhanced Nucleation of Isotactic Polypropylene in Limited Space

The nucleation rate was measured by directly counting the number of nuclei, which were developed while an isotactic polypropylene melt was flowing under shear in a thin film. The nucleation rate was enhanced with an increased rate of shear, e.g., by a factor of 10 larger at the rate of shear of 14 s^?1 compared with the quiescent state, at 134°C. The ratio of the shear‐enhanced nucleation rate to the nucleation rate in the quiescent state was larger at a higher temperature of crystallization, i.e., about 10 times at 134°C to 590 times at 140°C. The increase of the nucleation rate under shear flow was explained by a reduction of the lateral and end (fold) surface free energies; the product σ _s ² σ _e decreased to 3.2×10^?7 for the sheared melt, from 6.0×10^?7 (J m^?2)³ for the isotropic state. The free energy reduction was caused by transition of the nucleus formation mode from three‐dimensional folded chain nuclei to two‐dimensional bundle nuclei, in which chains lie down on the glass substrate, aligning parallel to the flow direction.     

Crystallization of poly(ethylene-co-octene): II Melt memory effects on first order kinetics

Dilatometric and X-ray scattering experiments of the crystallization kinetics of a sample of poly(ethylene-co-octene) show pronounced melt memory effects, i.e., the shapes of isotherms and characteristic times vary systematically with the temperature of the melt prior to cooling to the crystallization temperature. The temperature range of the effect is limited; crystallization kinetics remains constant below a melt temperature Tm l and above a melt temperature Tmh and varies only in-between. Analysis shows that the melt memory effect is caused by a variation of the characteristic time of a first order crystallization process. The process can be assigned to the in-filling of crystallites into objects of a previously generated precursor structure.     

β-MODIFICATION OF ISOTACTIC POLYPROPYLENE: PREPARATION,STRUCTURE, PROCESSING,PROPERTIES, AND APPLICATION

The methods of preparation and formation of supermolecular structures in quiescent and sheared melts and the properties of the β-modification of isotactic polypropylene (β-iPP) are reviewed. The introduction of selective β-nucleants is the most reliable method for preparation of samples rich in β-modification or of pure β-iPP. The advantages and drawbacks of the known β-nucleating agents are summarized. It is emphasized that pure β-iPP can be prepared under laboratory and processing conditions in the presence of highly active and selective β-nucleants. Nevertheless, there are no literature data—apart from that of the author's groups—which evidenced unambiguously the formation of pure β-iPP. It hints at the insufficient selectivity of β-nucleants used or at the inappropriate crystallization or melting conditions applied by other scientists. The structure formation during the high-temperature hedritic crystallization is discussed comprehensively and illustrated by polarized light microscopy and scanning electron microscopy micrographs. Some specific features of β-iPP, namely the high- and low-temperature growth transition, the restricted temperature range of the formation of pure β-iPP, and the unique melting and recrystallization characteristics (melting and annealing memory effect) are summarized. It was emphasized that impact strength and toughness of β-iPP markedly exceed those of α-iPP. Processing of β-nucleated iPP and application of β-nucleated iPP is described briefly.     

A Novel Strategy for Achieving High Melt Strength Polypropylene and an Investigation of Its Foamability

A novel and feasible strategy for preparing high melt strength polypropylene (HMSPP) was developed by a melt grafting reaction in the presence of macro-monomer vinyl polydimethylsiloxane (VS), co-monomer styrene (St), and initiator benzoyl peroxide through a one-step reactive extrusion. The rheological behaviors, melt strength, and foaming ability of HMSPP were studied. The results showed that VS and St were successfully grafted onto polypropylene (PP), and the weight average molecular weight, molecular weight distribution, and melt strength of HMSPP were dramatically increased compared with those of the virgin isotactic polypropylene (iPP). Especially, the melt strength of HMSPP increased from 0.022 N for the virgin iPP to 0.29 N, which made the foamability of HMSPP significantly improved when supercritical carbon dioxide was used as the blowing agent. The foaming condition was optimized to 160°C and 14 MPa, for which HMSPP foams with a high expansion ratio of 66 times and a high cell density of about 5.8×10⁷ cell/cm³ were obtained, while the virgin iPP did not yield foams with good cell structure. Moreover, the resultant HMSPP could be foamed in a remarkably wide temperature range from 145°C to 165°C, which would be of great significance for industrial application.