Characterization of linear low-density polyethylene: Cross-fractionation according to copolymer composition and molecular weight

The structure of ethylene copolymers modified by α-olefins has become an area of intense investigation since the successful commercialization of so-called linear low-density polyethylene (LLDPE) resins. The molecular structure of a series of typical commercial LLDPE copolymers was investigated and compared to LDPE and HDPE. The commercial LLDPE resins studied contained about 7% by weight of butene-1. The resins were fractionated according to short-chain branching content by a technique called temperature rising elution fractionation. Size exclusion chromatography, x-ray diffraction, ¹³C nuclear magnetic resonance, intrinsic viscosity, and differential scanning calorimetry were used to fully characterize the whole polymers as well as fractions of a selected LLDPE resin. A broad set of data was assembled in this work to investigate the short-chain branching, long-chain branching, and the molecular-weight distribution of these commercial resins. The melting behavior of the LLDPE resins was found to be strikingly different from that of LDPE and HDPE. The broad and multimodal melting envelope of the LLDPE resins was found to be due to a broad and multimodal short-chain branching distribution. No significant long-chain branching was found in the LLDPE resins. The short-chain branching was found to decrease with the increase of molecular weight in a typical commercial LLDPE resin. The unique physical properties of these resins are certainly strongly controlled by the expression of the distinctive heterogeneous comonomer incorporation in the solid-state morphological structure. The physical and mechanical properties of these materials should be ultimately understandable on the basis of the unique morphology which results from the extremely heterogeneous incorporation of modifying α-olefin in these commercial LLDPE resins.     

Calibration curve establishment and fractionation temperature selection of polyethylene for preparative temperature rising elution fractionation

A series of copolymers of ethylene with 1-hexene synthesized using a metallocene catalyst are selected and mixed. The blend is fractionated via preparative temperature rising elution fractionation(P-TREF). All fractions are characterized via high-temperature gel permeation chromatography(GPC), 13 C nuclear magnetic resonance spectroscopy(13C-NMR), and differential scanning calorimetry(DSC). The changes in the DSC melting peak temperatures of the fractions from P-TREF as a function of elution temperature are almost linear, thereby providing a reference through which the elution temperature of TREF experiments could be selected. Moreover, the standard calibration curve(ethylene/1-hexene) of P-TREF is established, which relates to the degree of short-chain branching of the fractions. The standard calibration curve of P-TREF is beneficial to study on the complicated branching structure of polyethylene. A convenient method for selecting the fractionation temperature for TREF experiments is elaborated. The polyethylene sample is fractionated via successive self-nucleation and annealing(SSA) thermal fractionation. A multiple-melting endotherm is obtained through the final DSC heating scan for the sample after SSA thermal fractionation. A series of fractionation temperatures are then selected through the relationship between the DSC melting peak temperature and TREF elution temperature.     

ANALYSIS OF BRANCHING DISTRIBUTION IN POLYETHYLENES BY DIFFERENTIAL SCANNING CALORIMETRY

Short chain branching has been characterized using thermal fractionation, a stepwise isothermal crystallizationtechnique, followed by a melting analysis scan using differential scanning calorimetry. Short chain branching distributionwas also characterized by a continuous slow cooling crystallization, followed by a melting analysis scan. Four differentpolyethylenes were studied: Ziegler-Natta gas phase, Ziegler-Natta solution, metallocene, constrained-geometry single sitecatalyzed polyethylenes. The branching distribution was calculated from a calibration of branch content with meltingtemperature. The lamellar thickness was calculated based on the thermodynamic melting temperature of each polyethyleneand the surface free energy of the crystal face. The branching distribution and lamellar thickness distribution were used tocalculate weight average branch content, mean lamellar thickness, and a branch dispersity index. The results for the branchcontent were in good agreement with the known comonomer content of the polyethylenes. A limitation was that high branchcontent polyethylenes did not reach their potential crystallization at ambient temperatures. Cooling to sub-ambient wasnecessary to equilibrate the crystallization, but melting temperature versus branch content was not applicable after cooling tobelow ambient because the calibration data were not performed in this way.     

Metallocene ethylene-1-octene copolymers: Influence of comonomer content on thermo-mechanical, rheological, and thermo-oxidative behaviours before and after melt processing in an internal mixer

The influence of the comonomer content in a series of metallocene-based ethylene-1-octene copolymers (m-LLDPE) on thermo-mechanical, rheological, and thermo-oxidative behaviours during melt processing were examined using a range of characterisation techniques. The amount of branching was calculated from ¹³C NMR and studies using differential scanning calorimetry (DSC) and dynamic mechanical analysis (DMA) were employed to determine the effect of short chain branching (SCB, comonomer content) on thermal and mechanical characteristics of the polymer. The effect of melt processing at different temperatures on the thermo-oxidative behaviour of the polymers was investigated by examining the changes in rheological properties, using both melt flow and capillary rheometry, and the evolution of oxidation products during processing using infrared spectroscopy.The results show that the comonomer content and catalyst type greatly affect thermal, mechanical and oxidative behaviour of the polymers. For the metallocene polymer series, it was shown from both DSC and DMA that (i) crystallinity and melting temperatures decreased linearly with comonomer content, (ii) the intensity of the β-transition increased, and (iii) the position of the tan δ_max peak corresponding to the α-transition shifted to lower temperatures, with higher comonomer content. In contrast, a corresponding Ziegler polymer containing the same level of SCB as in one of the m-LLDPE polymers, showed different characteristics due to its more heterogeneous nature: higher elongational viscosity, and a double melting peak with broader intensity that occurred at higher temperature (from DSC endotherm) indicating a much broader short chain branch distribution.The thermo-oxidative behaviour of the polymers after melt processing was similarly influenced by the comonomer content. Rheological characteristics and changes in concentrations of carbonyl and the different unsaturated groups, particularly vinyl, vinylidene and trans-vinylene, during processing of m-LLDPE polymers, showed that polymers with lower levels of SCB gave rise to predominantly crosslinking reactions at all processing temperatures. By contrast, chain scission reactions at higher processing temperatures became more favoured in the higher comonomer-containing polymers. Compared to its metallocene analogue, the Ziegler polymer showed a much higher degree of crosslinking at all temperatures because of the high levels of vinyl unsaturation initially present.     

Characterization of comonomer distributions in ethylene/diene copolymers by 13C-NMR,and using the segregation fractionation technique by DSC and DMTA

Ethylene and linear, nonconjugated dienes were copolymerized with the catalyst system Cp₂ZrCl₂/methylaluminoxane (MAO). The comonomer incorporation and the relationships between structure and properties were evaluated by NMR and by thermal techniques, especially the segregation fractionation technique (SFT) using DSC and dynamic mechanical thermal analysis (DMTA). The ethylene-1,5-hexadiene (HD) copolymers showed different behavior than the others and it was possible to incorporate as much as 7 mol % of the hexadiene comonomer into soluble polymer compared with only 2.4 mol % of the 1,7-octadiene (OD) and 7-methyl-1,6-octadiene (MOD). The melting endotherms of the HD copolymers obtained after segregation fractionation were very much like corresponding endotherms of high-density polyethylene (HDPE) and a population with nearly one lamellar thickness was postulated. This is in agreement with cyclic structure formation and absence of branching with crosslinking for these copolymers. The OD and MOD copolymers, on the other side, showed endotherms with several peaks indicating a distribution of the comonomers along the chain. Lamellar thickness distributions were calculated from the melting endotherms by using the Gibbs–Thomson equation. The DMTA measurements confirmed the absence of branches in the HD copolymers and the presence of branches in the OD and the MOD copolymers. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 2379–2389, 1999     

Advanced Characterization of Propylene-Based Copolymers and Olefin Block Copolymers

Summary: The newly developed interactive separation of polyolefins by high temperature liquid chromatography (HTLC) provides new information about the chemical composition distribution of polyolefin elastomers. The technique has the advantage of being quantitative in its separation, and has high resolution for the separation of polyolefins by their chemical composition without influence by cocrystallization. Chemical composition distributions can be determined for individual polymers and blends which contain the full range of comonomer typically present in polyethylene and poylypropylene homopolymers, semi-crystalline copolymers, and amorphous copolymers. HTLC analysis in combination with the other fractionation techniques, such as DSC, TREF, NMR, and xylene fractionation, can be used to estimate the amount of olefin block copolymer present in a block composite produced by chain shuttling catalysis.     

Effect of short-chain branching on the morphology of LLDPE-oriented thin films

High-density polyethylene and randomly branched linear low-density polyethylene of varying branch length and content were used to produce oriented thin films. Sample morphology was investigated using transmission electron microscopy (TEM), differential scanning calorimetry (DSC), and dynamic mechanical thermal analysis (DMA). Gelation studies suggested that the film preparation technique may have involved gel-drawing. DSC characterization of samples with approximately equal average branch content revealed very different melting behavior, suggesting differences in crystal size distributions. This was attributed to variations in the distribution of branches within samples. For similar branching distributions, the average melting temperature (and, similarly, crystal size) generally decreased as branch content increased. This was corroborated by TEM, with which crystal thickness was found to decrease as branch content increased. TEM further revealed that the lateral alignment of mosaic blocks and the resultant lamellar character of the thin films was obscured as branch content increased, a result of reduced crystal size, crystallinity, and possibly increased interphase content. DMA of compression-molded material revealed the presence of a beta peak in branched samples only. Moreover, the alpha transition temperature shifted to lower temperatures as branch content increased.     

Crystallization and melting of narrow composition distribution polyethylenes: Investigation and implications of crystal thickening

The crystal structure produced during the isothermal crystallization of polyethylene (PE) copolymers with a broad range of comonomer concentrations was determined by the measurement of the melting endotherms directly after crystallization. PE copolymers with higher concentrations of short‐chain branches (≥10 branches per 1000 total carbon atoms) exhibited strong resistance to crystal thickening during isothermal crystallization. Negligible thickening, estimated to be only about 0.1 nm in 10 min of isothermal crystallization, was observed. The side‐chain branches apparently acted as limiting points of chain incorporation into the crystals, which exhibited great resistance to the modification of their position, that is, crystal thickening. Even with long periods (up to 8 h) of isothermal storage, crystal thickening was very small or negligible, about 0.3 nm. The crystal thickness was calculated from differential scanning calorimetry data. The behavior of copolymers with lower branching concentrations and the unbranched PE homopolymer was quite different from that of the copolymers with higher branching. Polymers with low or no branching exhibited the initial crystallization of a thinner crystal population, which thickened substantially with increasing time. The thickening observed for these lower or unbranched polymers was an order of magnitude larger, that is, 1.6–2.0 nm in 10 min of isothermal crystallization. Copolymers with higher concentrations of branching had relatively short sequence lengths of ethylene units between branch points, and this resulted in strong control over the crystal thickness by the branch points and great resistance to crystal thickening, even with long times of isothermal crystallization. Copolymers with low concentrations of branching had relatively long sequence lengths of ethylene units between branch points, and this resulted in little control over the crystal thickness by the branch points and rapid crystal thickening upon isothermal crystallization. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 235–246, 2003     

Block Index for Characterizing Olefin Block Copolymers

Summary: Olefin block copolymers produced by chain shuttling catalysis exhibit crystallinity characteristics that are distinct from what would be expected for typical random olefin copolymers with comparable monomer compositions produced from either ‘single-site’ or heterogeneous catalysis. Olefin block copolymers produced by chain shuttling catalysis have a statistical multiblock architecture. A unique structural feature of olefin-based block copolymers is that the intra-chain distribution of comonomer is segmented (statistically non-random). Fractionating an olefin block copolymer by preparative temperature rising elution fractionation, TREF, results in fractions that have much higher comonomer content than comparable fractions of a random copolymer collected at an equivalent TREF elution temperature. We have developed a “block index” methodology which quantifies the deviation from the expected monomer composition versus the analytical temperature rising elution fractionation, ATREF, elution temperature. When interpreted properly, this index indicates the degree to which the intra-chain comonomer distribution is segmented or blocked. The unique crystallization behavior of block copolymers determine the magnitude of the block index values because the highly crystalline segments along an otherwise non-crystalline chain tend to dominate the ATREF (and DSC) temperature distributions.     

Melting behavior of ethylene copolymers and branched polyethylenes

Prior research on the melting behavior of ethylene copolymers and branched polyethylenes could not be effectively evaluated since there were large differences in the levels of comonomer contents. The present research was undertaken to determine additional data so that an overall evaluation could be made. A consideration of the experimental data of the present work and earlier research data showed that methyl side groups caused less diffuse melting and less melting point depression than either ethyl groups or polyethylene branches. In addition, it was found that the Flory equation can be used to describe the relation of melting point depression to foreign group concentration for propylene copolymers. The equation did not hold for 1-butene-ethylene copolymers or branched polyethylenes. For these materials the Wunderlich modification of the Flory equation applied. Activity values for both 1-butene-ethylene copolymers and branched polyethylenes gave a common correlation with foreign groups. Enthalpy and entropy fusion data for ethylene copolymers and branched polyethylenes were also determined. It was also shown that good agreement was found between crystallinities for these materials determined independently by differential thermal analysis and x-ray analysis.     

Thermal properties of ethylene/long chain α-olefin copolymers produced by metallocenes

Metallocene type copolymers of ethylene with the α-olefins 1-octene, 1-tetradecene and 1-octadecene were characterized by dynamic scanning calorimeter (DSC) and by dynamic mechanical analysis (DMA). At a similar comonomer content above 3 mol%, the higher α-olefins gave lower melting points, crystallinities and densities than 1-octene. In DSC a separation technique sorting the crystalline sequence lengths of the polymer into groups was applied, and DSC index, DI, which gave a semiquantitative idea of the chemical homogeneity of the comonomer compositional distributions. By DMA the storage modulus as an indicator of stiffness and loss modulus and loss tangent as a measure of the effect of branching on the β relaxations were studied. The DMA measurements showed the loss modulus maximum to be a more sensitive value than the loss tangent maximum for the characterization of the comonomer distribution. The intensity of the β transition of 1-octadecene did not increase with increasing branching in contrast to the situation for 1-octene and 1-tetradecene copolymers.     

Some simulations on crystallinity in a typical linear low-density polyethylene

Crystallinity in ethylene/1-hexene copolymers, a type of linear low-density polyethylene, was investigated by Monte Carlo simulations. The comonomer distributions generated in the simulated chains and the melting temperatures of real chains were used to estimate the minimum crystallite thickness, which is the critical quantity for simulating crystallization in any type of polymer. Simulated values of this thickness were in good agreement with values calculated from Raman longitudinal acoustic mode (LAM) spectroscopy, except for very low 1-hexene mole fractions, where there were presumably complications from high melt viscosities and chain entanglements. The use of this information in estimating properties of these copolymers is illustrated by some preliminary results on the effects of varying amounts of this comonomer on the sizes and numbers of the polyethylene crystallites.     

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     

TIME-TEMPERATURE-MISCIBILITY AND MORPHOLOGY OF POLYOLEFIN BLENDS

Miscibility and crystallization have been studied for polypropylene-polyethylene and polyethylene-polyethyleneblends. In the case of the polypropylene blends the composition of interest is 20% polypropylene. At this composition thepolypropylene has been found to be soluble in linear low density polyethylene but insoluble in high, low and very lowdensity polyethylenes. The miscibility has been concluded from the crystallization kinetics and polarised optical microscopywith a hot stage. Polyethylene-polyethylene blends have been formed from polymers with similar average branching contentbut where they have different melting temperatures. Important consequences are to introduce long branches into apolyethylene that only has short branches, and to modify the morphology of a polyethylenes so that haze, gloss and strainhardening are improved. Polyethylene blends must be developed after careful consideration of the branch content anddistribution within each of the constituents. It is not sufficient to simply blend polyethylenes, with the desired range ofproperties, without regard to the miscibility of the blend composition.     

TMDSC analysis of single-site copolymer blends after thermal fractionation

Temperature-modulated differential scanning calorimetry (TMDSC) has been used to study the melting of a series of blends containing linear low-density polyethylene (LLDPE) and very low-density polyethylenes (VLDPE) with long chain branches. After the blends were subjected to different thermal histories including thermal fractionation by stepwise isothermal cooling, they were examined by TMDSC. TMDSC curves have been interpreted in terms of a combination of the reversing and non-reversing specific heats that result from reversible and irreversible events at the time and temperature, which they are detected, respectively. It was found that crystals formed at different crystallisation conditions had different internal order; hence they showed different amounts of reversing and non-reversing contributions. There is no exothermic activity seen in the non-reversing signal for the thermally fractionated polymers and their blends suggesting formation of crystals approaching equilibrium. In contrast, polymers and blends cooled at 10°C min^-1 cooling rate showed large exothermic contributions corresponding to irreversible effects. In addition, a true reversible melting contribution is also detected for both fast-cooled and thermally-fractionated samples during the quasi-isothermal measurements. This revised version was published online in July 2006 with corrections to the Cover Date.     

Morphology of homogeneous copolymers of ethylene and 1‐octene. III. Structural changes during heating as revealed by time‐resolved SAXS and WAXD

The structural changes of two linear polyethylenes, LPEs, with different molar mass and of two homogeneous copolymers of ethylene and 1‐octene with comparable comonomer content but different molar mass were monitored during heating at 10 °C per minute using synchrotron radiation SAXS. Two sets of samples, cooled at 0.1 °C per minute and quenched in liquid nitrogen, respectively, were studied. All LPEs display surface melting between room temperature and the end melting temperature, whereas complete melting, according to lamellar thickness, only occurs at the highest temperatures where DSC displays a pronounced melting peak. There is recrystallization followed by isothermal lamellar thickening if annealing steps are inserted. The lamellar crystals of slowly cooled homogeneous copolymers melt in the reverse order of their formation, that is, crystals melt according to their thickness. Quenching creates unstable crystals through the cocrystallization of ethylene sequences with different length. These crystals repeatedly melt and co‐recrystallize during heating. The exothermic heat due to recrystallization partially compensates the endothermic heat due to melting resulting in a narrow overall DSC melting peak with its maximum at a higher temperature than the melting peak of slowly cooled copolymers. With increasing temperature, the crystallinity of quenched copolymers overtakes the one of slowly cooled samples due to co‐recrystallization by which an overcrowding of leaving chains at the crystal surfaces is avoided. © 2000 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 38: 1975–1991, 2000     

Morphological explanation of the extraordinary fracture toughness of linear low density polyethylenes

The fracture toughness of commercial linear low-density polyethylenes (LLDPE) has been found to be extraordinarily high relative to commercial low-density (LDPE) and high-density (HDPE) polyethylenes in previously reported investigations. The present investigation shows that this extraordinary fracture toughness cannot be explained by differences in molecular structure variables, such as molecular weight, long-chain and short-chain branching, fractional crystallinity, and comonomer content. Instead, the presence of a second soft phase, which was extractable with a weak solvent, in a hard semicrystalline matrix was discovered by morphological investigations of LLDPE resins. This second phase arises from the extreme compositional heterogeneity of the copolymers which comprise these LLDPE resins. No evidence for a similar morphological entity was found in LDPE and HDPE resins. This finding provides persuasive evidence that this very-low-crystallinity second phase performs a function similar to that of the rubberlike second phase in other high impact resins and, thus, leads to the observed extraordinary fracture toughness of LLDPE resins. Evidence for the nature and existence of this second phase is given from temperature-rising elution fractionation and scanning electron microscopy investigations.     

Characterization of Polyethylene Nascent Powders Synthesized with TpTiCl2(OR) Catalysts

Summary: Different kinds of polyethylene and ethylene-1-hexene copolymers were synthesized with TpTiCl₂(OR) (Tp = hydrotris(pyrazolyl)borate; R = Et, i-Pr, n-Bu) catalysts with and without H₂. The polymers were characterized by ¹³C NMR, capillary viscosimetry or GPC, and DSC. The homopolymers showed properties characteristic of ultra-high molecular weight polyethylenes (UHMWPE) with linear structure and high density polyethylenes (HDPE) with molecular weights in the range of commercial grades under hydrogen atmosphere. The copolymers showed a 1-hexene incorporation up to 6 mol-%. Important differences in the thermal properties were observed between the first DSC (nascent powders) and the second DSC heatings (melt-crystallized samples), which evidenced the molecular weights influence on the melt-crystallized samples.     

Melting Point and Composition Distribution of Polyolefins by Fractionation

The fractionation technique described in this paper was used to characterize the melting-point, monomer, and blocking distributions for polymers and copolymers. It is different from the molecular-weight fractionation technique in that the fractions are obtained by using a single solvent to extract the solid polymer below its melting point at stepwise-increasing temperatures. The reproducibility of this technique is excellent, and the technique is sufficient to distinguish pellet-to-pellet variation in a commercially available polypropylene. It was used to show the influence of preparation variables on the melting-point distributions of polyethylene and polypropylene and on the monomer and blocking distribution of copolymers, and to distinguish copolymers from blends.     

Carbon-13 NMR of ethylene-1–olefin copolymers: Extension to the short-chain branch distribution in a low-density polyethylene

As model polymers for isolated short-chain branches in low-density polyethylene, a series of ethylene–1-olefin copolymers was examined by use of ¹³C NMR at 25.2 MHz. An array of ¹³C resonances was observed that could be associated independently with methyl through amyl branches. The ¹³C chemical shifts became insensitive to branch length with hexyl and longer branches. Assignments of the various carbon resonances associated with branching were accomplished by using off-resonance decoupling techniques and the behavior of alkane chemical shifts previously observed by other investigators. The ratio of certain backbone and branch resonances could be used to establish the short-chain branch distribution in a low-density polyethylene.