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     

Phase Transformation Behavior of Polylactide Probed by Small Angle Light Scattering and Calorimetry

Small angle light scattering (SALS) and differential scanning calorimetry DSC have been applied to investigate the melting of spherulites isothermally crystallized polylactide. At an isothermal crystallization temperature high enough, pure α‐phase crystals are formed. Exposed to a temperature gradient, the crystals first melt and then recrystallize before they finally melt. With decreasing crystallization temperature, an increasing fraction of polylactide is crystallizing in the less stable α ^′‐phase. α ^′‐crystals also melt upon increasing the temperature but recrystallize to the more stable α‐phase. A constant spherulite size is revealed by SALS for both processes, the α/α and α ^′/α melt‐recrystallization, until completion of the final melting, thereby supporting integrity of the spherulites throughout the entire processes. Joint DSC and SALS experiments demonstrate that the depolarized scattering invariant correlates with the heat flow recorded by DSC and thus offer an alternative measure for the degree of crystallinity. The following mechanism is identified for both processes: initial melting and recrystallization overlay each other. Crystallinity is not fully recovered upon recrystallization because only part of the original lamellae survives the melt‐recrystallization, though with an increased thickness. While lamellae are melting and reforming or simply transforming their phase, the spherulites survive the process until final melting. © 2019 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2019 , 57, 1483–1495     

Features of the hedritic morphology of β‐isotactic polypropylene studied by atomic force microscopy

The lamellar organization of melt‐crystallized β‐isotactic polypropylene was studied by atomic force microscopy (AFM) after permanganic etching. Hedritic objects grown at a high crystallization temperature (140–143 °C) were investigated. Essential features of the hedritic development were revealed by the characteristic projections exposed at the sample surface. A three‐dimensional view of the morphology was obtained by AFM. Hedritic growth proceeded mainly by branching around screw dislocations resulting in new lamellae that further developed. Successive lamellar layers often diverged. Deviation from the planar lamellar habit was observed, varying with the position within the hedrite. Twisting of the lamellae also was observed occasionally in the vicinity of the screw dislocations. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 672–681, 2000     

Crystallization and melting of polyethylene copolymers: Differential scanning calorimetry and atomic force microscopy studies

The Hoffman–Lauritzen theory of secondary, surface nucleation and growth was primarily relied upon for about 40 years after its introduction in about 1960 to rationalize the crystallization of flexible chain polymers into lamellar crystals. However, in about 1998, Strobl and coworkers introduced a different model for crystallization, based on the stage‐wise formation of lamellae. Two major components of this model were as follows: (1) the concept of the formation of a mesomorphic melt as a precursor to crystallization and (2) the control of the melting temperature range of lamellar crystals of homogeneous polyolefin copolymers by an inner degree of order or perfection rather than on the crystal thickness. The first concept is in disagreement with the HL theory and the second with the Gibbs‐Thomson theory, which associates melting temperature with lamella thickness. In the present study, differential scanning calorimetry and atomic force microscopy were successfully employed to monitor the in situ quiescent crystallization of polyethylene homopolymer and copolymer. In the present study, evidence was not found to support the concept of lamellae with equal thickness melting over a broad temperature range. Some evidence was found that might be interpreted to support the concept of a mesomorphic melt as a precursor to crystallization. At present, the model promoted by Strobl and coworkers appears to be at an uncertain stage at which strong proof or disproof are not available. However, this alternative model has injected a new vitality into the study of crystallization of flexible chain polymers. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 2369–2388, 2006     

The morphology of poly(vinylidene fluoride) crystallized from blends of poly(vinylidene fluoride) and poly(ethyl acrylate)

A combined optical and electron microscopical study has been carried out of the crystallization habits of poly(vinylidene fluoride) (PVF₂) when it is crystallized from blends with noncrystallizable poly(ethyl acrylate) (PEA). The PVF₂/PEA weight ratios were 0.5/99.5,5/95, and 15/85. Isothermal crystallization upon cooling the blends from the single-phase liquid region was carried out in the range 135–155°C, in which the polymer crystallizes in the α-orthorhombic unit cell form. The 0.5/99.5 blend yielded multilayered and planar lamellar crystals. The lamellae formed at low undercoolings were lozenge shaped and bounded laterally by {110} faces. This habit is prototypical of the dendritic lateral habits exhibited by the crystals grown from the same blend at high undercoolings as well as by the constituent lamellae in the incipient spherulitic aggregates and banded spherulites that formed from the 5/95 and the 15/85 blends, respectively. In contrast with the planar crystals grown from the 0.5/99.5 blend, the formation of the aggregates grown from the 5/95 blend is governed by a conformationally complex motif of dendritic lamellar growth and proliferation. The development of these aggregates is characterized by the twisting of the orientation of lamellae about their preferential b-axis direction of growth, coupled with a fan-like splaying or spreading of lamellae about that axis. The radial growth in the banded spherulites formed from the 15/85 blend is governed by a radially periodic repetition of a similar lamellar twisting/fan-like spreading growth motif whose recurrence corresponds to the extinction band spacing. This motif differs in its fan-like splaying component from banding due to just a helicoidal twisting of lamellae about the radial direction. © 1993 John Wiley & Sons, Inc.     

Confined crystallization in lamellae forming poly(3-(2′-ethyl)hexylthiophene) (P3EHT) block copolymers

Charge transport in poly(3-alkylthiophene)s (P3AT)s is closely linked to the nanoscale organization of crystallites. Block copolymer morphologies provide an ideal platform to study crystallization as the chain ends are tethered at a known interface in a well-defined geometry. The impact of soft versus hard confinement on P3EHT crystallization was studied using poly(3-(2′-ethyl)hexylthiophene) (P3EHT) containing diblocks with both rubbery poly(methyl acrylate) (PMA) and glassy polystyrene (PS) blocks. Here, P3EHT's lower melting point relative to the commonly studied poly(3-hexylthiophene) (P3HT) facilitated its confined crystallization and makes it an ideal model system. While transmission electron microscopy (TEM) and small angle X-ray scattering (SAXS) revealed well-ordered lamellar morphologies both in the melt and post-crystallization for both sets of diblocks, the glassy blocks inhibit confined crystallization of P3EHT relative to rubbery matrix blocks. Analysis of aligned diblocks by both SAXS and wide angle X-ray scattering (WAXS) revealed that the P3EHT chain axis aligns perpendicular to domain interfaces, allowing preferential growth of the alkyl-chain and π–π stacking directions parallel to lamellae. Finally, it was shown that following diblock self-assembly in the melt, crystallite growth drives expansion of microdomains to match the P3EHT contour length. It was concluded that P3EHT chains adopted an extended conformation within confined crystallites due to the rigid nature of polythiophenes relative to flexible chain crystalline polymers. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2016, 54, 205–215     

Ring‐banded spherulites in poly(pentamethylene terephthalate): A model of waving and spiraling lamellae

A new aryl polyester, poly(pentamethylene terephthalate) (PPT) with five methylene groups in the repeat unit, was synthesized. Its multiple‐melting behavior and crystal structure were analyzed with differential scanning calorimetry and wide‐angle X‐ray diffraction. In addition, the spherulitic/lamellar morphology of melt‐crystallized PPT was investigated. Typical Maltese‐cross spherulites (with no rings) were seen in melt‐crystallized PPT at low temperatures (70–90 °C), but ring patterns were seen in PPT crystallized only at temperatures ranging from 100 to 115 °C, whereas rings disappeared with crystallization above 120 °C. The mechanisms of the rings in PPT were explained with several coordinated directional changes (wavy changes, twisting changes, and combinations) in the lamellae during growth. Scanning electron microscopy, in combination with atomic force microscopy, further proved that the ringed spherulites originated from the aggregation of sufficient numbers of edge‐on lamellar crystals; the radial‐growth edge‐on/flat‐on lamellae could be twisted and/or waved to form realistic band patterns. A postulated model properly described a possible origin of the ring bands through combined mechanisms of waving (zigzagging) and twisting (spiraling) of the lamellae during crystallization. Superimposed twisting and/or wavy models during crystallization were examined as examples. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 42: 4421–4432, 2004     

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

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

Correlation of the melting behavior and copolymer composition distribution of Ziegler–Natta‐catalyst and single‐site‐catalyst polyethylene copolymers

The multimodal differential scanning calorimetry melting endotherms observed for commercial linear low‐density polyethylenes are due to broad and multimodal short‐chain‐branching distributions. Multiple peaks, observed in melting endotherms of isothermally melt‐crystallized and compositionally homogeneous polyethylene copolymers are due to intrachain heterogeneity. This intrachain heterogeneity is quantified by the distribution of ethylene sequence lengths within the chains. These compositionally homogeneous copolymers undergo a primary crystallization, which produces a population of thicker lamellae, creating a network that places severe restrictions on segment transport in subsequent secondary crystallization, which produces a population of thinner crystals. The restrictions on segment transport imposed by the initial network created by the primary crystallization of thicker lamellae severely limits the total crystallinity achieved in the random copolymers studied. The solution crystallization of such copolymers produces a continuous distribution due to more facile segment transport in a dilute solution, in contradistinction to the multimodal distribution produced in the melt crystallization. © 2001 John Wiley & Sons, Inc. J Polym Sci Part B: Polym Phys 39: 2800–2818, 2001     

Self‐decelerated crystallization in poly(butylene terephthalate)/poly(ε‐caprolactone) blends

Isothermal crystallization of poly(butylene terephthalate) (PBT) blended with oligomeric poly(ε‐caprolactone) (PCL) is investigated by polarized optical microscopy and differential scanning calorimetry at various temperatures (T_c). The growth rate of PBT spherulites is found to depend on time (t), as the spherulite radius (r) linearly increases with t at the early stages of crystallization (r ∝ t), then, with the progress of phase transition, the spherulite radius becomes dependent on the square root of the time (r ∝ t^1/2) until termination of crystal growth. The nonlinear advance of the crystal growth front is caused by a varied composition of the melt phase in contact with the growing crystals, due to diffusion of mobile PCL chains away from the spherulite surface. The melt phase becomes spatially inhomogeneous, causing self‐deceleration of PBT crystallization until a limit composition that prevents further crystallization is reached in the melt. The maximum crystallinity achievable during isothermal crystallization decreases with T_c. The lowering of the temperature after termination of the isothermal crystallization allows to complete the crystal growth, but the final developed crystallinity still depends on T_c, being lower at higher T_cs. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 3148–3155, 2007     

New insight into melting and crystallization behavior in semicrystalline poly(ethylene terephthalate)

After isothermal crystallization, poly(ethylene terephthalate) (PET) showed double endothermic behavior in the differential scanning calorimetry (DSC) heating scan. During the heating scans of semicrystalline PET, a metastable melt which comes from melting thinner lamellar crystal populations formed between the low and the upper endothermic temperatures. The metastable melt can recrystallize immediately just above the low melting temperature and form thicker lamellae than the original ones. The thickness and perfection depends on the crystallization time and crystallization temperature. The crystallization kinetics of this metastable melt can be determined by means of DSC. The kinetics analysis showed that the isothermal crystallization of the metastable PET melt proceeds with an Avrami exponent of n = 1.0 ∼ 1.2, probably reflecting one‐dimensional or irregular line growth of the crystal occurring between the existing main lamellae with heterogeneous nucleation. This is in agreement with the hypothesis that the melting peaks are associated with two distinct crystal populations with different thicknesses. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 53–60, 2000     

AFM-tip-induced crystallization of poly(ethylene oxide) melt droplets

The AFM-tip-induced crystallization of poly(ethylene oxide) (PEO) melt droplets was studied. The melt droplets with a height of 50–100 nm and a lateral size of 2–3 μm were obtained by melting the PEO ultra-thin films on a mica surface. For the PEO samples with average molecular weights (M _n) ranging from 1.0 × 10³ g/mol to 1.0 × 10⁴ g/mol, the lateral perturbation from the AFM tip in the hard-tapping or nanoscratch modes could not induce the growth of the flat-on lamellae. In contrast, under AFM nanoindentation mode, the tip-induced crystallization occurred when a sufficiently high vertical tip force was applied to the melt droplets of PEO with M _n ⩾ 1.0 × 10⁴ g/mol. Moreover, the experimental results indicated that the AFM-tip-induced crystallization of PEO in the nanoindentation process had molecular weight dependence. Translated from Acta Polymerica Sinica, 2006, (4): 553–556 (in Chinese)     

The influence of thermoelastomers on the crystallization behavior of isotactic polypropylene under shear

The crystallization behaviors of isotactic polypropylene (iPP) and its blends with thermoelastomers have been investigated with in situ X‐ray scattering and optic microscopy. At quiescent condition, the crystallization kinetics of iPP is not affected by the presence of elastomers; while determined by the viscosity, the differences are observed on sheared samples. With a fixed shear strain, the crystallization rate increases with increasing the shear rate. The fraction of oriented lamellar crystals in blends is higher than that in pure iPP sample, while the percentage of β phase is reduced by the presence of the elastomers. On the basis of experimental results, no direct correlation among the fraction of oriented lamellae, the percentage of β phase, and growth rate can be deduced. The evolution of the fraction of oriented lamellae supports that shear field promotes nucleation rather than growth process. Shear flow induces the formation of nuclei not only with preferring orientation but also with random orientation. The total density of nuclei, which determines the crystallization kinetics, does not control the ratio between nuclei with and without preferring orientation, which determines the fraction of oriented lamellae. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 1188–1198, 2006     

Isothermal crystallization kinetics and melting behavior of poly(ethylene terephthalate)/barite nanocomposites

Poly(ethylene terephthalate) (PET)/Barite nanocomposites were prepared by direct melt compounding. The effects of PET‐Barite interfacial interaction on the dynamic mechanical properties and crystallization were investigated by DMA and DSC. The results showed that Barite can act as a nucleating agent and the nucleation activity can be increased when the Barite was surface‐modified (SABarite). SABarite nanoparticles induced preferential lamellae orientation because of the strong interfacial interaction between PET chains and SABarite nanoparticles, which was not the case in Barite filled PET as determined by WAXD. For PET/Barite nanocomposites, the Avrami exponent n increased with increasing crystallization temperature. Although at the same crystallization temperature, the n value will decrease with increasing SABarite content, indicating of the enhancement of the nucleation activity. Avrami analyses suggest that the nucleation mechanism is different. The activation energy determined from Arrhenius equation reduced dramatically for PET/SABarite nanocomposite, confirming the strong interfacial interaction between PET chains and SABarite nanoparticles can reduce the crystallization free energy barrier for nucleus formation. In the DSC scan after isothermal crystallization process, double melting behavior was found. And the double endotherms could be attributed to the melting of recrystallized less perfect crystallites or the secondary lamellae produced during different crystallization processes. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 655–668, 2009     

Origin of directional tear in blown films of ethylene/methacrylic acid copolymers and ionomers

Blown films of ethylene/methacrylic acid copolymers and ionomers can exhibit pronounced directional tear, meaning that a tear can propagate with much less resistance in a particular direction. However, films blown from the same resin can exhibit different preferred tear directions, which depend on the process conditions. Through wide‐ and small‐angle X‐ray scattering, we demonstrate that this directional tear behavior is a direct result of the orientation of the lamellar polyethylene crystallites in these films; tears propagate more readily between lamellae than through lamellae, as previously recognized for low‐density polyethylene homopolymer. Unlike polyethylene homopolymer, however, an increase in the blowup ratio during the film processing of ethylene/methacrylic acid copolymers and ionomers leads to a 90° rotation of the lamellae that form upon subsequent crystallization. The lamellar rotation arises from a change in the orientation of the row nuclei that form after the melt is inflated and produces a consequent rotation of the preferred tear direction. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 97–106, 2005     

Rapid small-angle and wide-angle x-ray studies of crystallization behavior in polymers

Small-angle and wide-angle x-ray scattering measurements, using a position-sensitive detector, were made during melt-crystallization of linear polyethylenes and PEO–PS–PEO triblock copolymer. The scattering measurements indicated that the triblock copolymer grew by the enlargement of regions in which lamellae are regularly stacked. During primary crystallization at higher temperatures similar behavior is observed in two linear polyethylenes. At lower temperatures, changes in the shape of small-angle scattering curves during the primary stage of crystallization indicate that amorphous gaps within the lamellar stacking become filled in. During secondary crystallization at higher temperatures new crystallites appear to grow between those formed in the primary stage. Concurrent decrease of the overall scattered intensity leads to the conclusion that secondary crystallization has two components: crystallization of new lamellae behind the spherulite growth front and the thickening of existing lamellae.     

Influence of deformation on irreversible and reversible crystallization of poly(ethylene‐co‐1‐octene)

The effect of uniaxial deformation and subsequent relaxation at ambient temperature on irreversible and reversible crystallization of homogeneous poly(ethylene‐co‐1‐octene) with 38 mol % 1‐octene melt‐crystallized at 10 K min was explored by calorimetry, X‐ray scattering, and Fourier transform infrared spectroscopy. At 298 K, the enthalpy‐based crystallinity of annealed specimens increased irreversibly by stress‐induced crystallization from initially 15% to a maximum of, at least, 19% when a permanent set of more than 200% was attained. The crystallinity increased by formation of crystals of pseudohexagonal structure at the expense of the amorphous polymer, and as a result of destruction of orthorhombic crystals. The stress‐induced increase of crystallinity was accompanied by an increase in the apparent specific heat capacity from 2.44 to about 2.59 J g^?1 K^?1, which corresponds to an increase of the total reversibility of crystallization from, at least, 0.10 to 0.17% K^?1. The specific reversibility calculated for 100% crystallinity increased from 0.67 to 0.89% K^?1 and points to a changed local equilibrium at the interface between the crystal and amorphous phases. The deformation resulted in typical changes of the phase structure and crystal morphology that involve orientation and destruction of crystals as well as the formation of fibrils. The effect of the decrease of the entropy of the strained melt on the reversibility of crystallization and melting is discussed. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 1223–1235, 2002     

The crystallization and morphology of melt-miscible polymer blends

The morphology and kinetics of crystallization from melt-miscible blends is reviewed for binary systems in which either one or both polymer components are crystallizable. In systems in which one component (component A) crystallizes first, the other component (B) may reside finally between spherulites, between growth arms (composed of a stack of A crystalline lamellae), or between crystal lamellae of A. The kinetics of component redistribution dictates which site must become primary. It is shown that the diffusivity D of the components in the melt and the velocity V of spherulite growth combine through the diffusion length δ = D/V to define the final location for component B and to also define whether spherulite propagation will be linear or parabolic in time. When crystallization of both components proceeds concurrently, by forming spherulites of A and of B, the spherulites are prone to interpenetrate or to form concentric spherulites. Cooperative crystallization, in which the kinetics of a rapidly crystallizing component and a slowly crystallizing component are both affected such that the two crystallize nearly simultaneously, is discussed. Finally, the competition between liquid-liquid phase separation and crystallization in systems with either an upper or lower critical solution temperature is reviewed.     

Study of bundle formation during crystallization in polymer blends

The development of texture which exists in polymer spherulites grown from single phase melts containing an appreciable amount of noncrystallizable material was investigated. This texture generally consists of lamellar bundles separated by amorphous regions, both of which are typically 0.1–1 μm thick. A space–time finite element model previously developed by us was used to simulate the growth of a group of polymer lamellae. The model determines the impurity concentration field in the melt surrounding the growing lamellae and tracks the growth of each lamella. Important variables are the initial melt concentration of noncrystallizable material, the mass diffusion coefficient of noncrystallizable species, lamellar thickness, long period, and the rate of molecular attachment at the growth front. Under certain conditions, bundles did indeed develop during the simulations. These results were used to predict bundle thicknesses. The predictions of bundle texture were compared to actual textures observed in blends of syndiotactic and atactic polystyrene. It was found both experimentally and numerically that bundle thickness was a strong function of crystallization temperature and a relatively weak function of both the initial composition of noncrystallizable species and the degree of crystallinity of the lamellar stack. © 1998 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 36: 873–888, 1998     

Sizes and interfacial free energies of crystallites formed from fractionated linear polyethylene

Replicas of fracture surfaces of fractions of linear polyethylene, which were crystallized at elevated temperatures for extended time periods, were examined by electron microscopy. Striated. lamella-type crystallites were observed for all molecular weights over the range 3.2 × 10³?5.7 × 10⁵. In agreement with Anderson's previous report, for molecular weights of 12,000 or less, the crystallite thicknesses were comparable to the extended chain length. As the molecular weight increased above this level, however, the crystallite sizes increased only slightly and hence at high molecular weights were very much smaller than the extended chain length. From the measured melting temperatures, crystallite interfacial free energies were calculated from the theory for the melting of finite size crystals comprised of chains of finite length. The crystallite interfacial free energy was found to increase with molecular weight. Based on these results, a crystallization process is outlined which allows for the formation of either extended chain crystallites, or crystallites whose size is much smaller than the extended chain length without any change in nucleation mechanism or arbitrary adjustment in growth mechanism with molecular weight.