Morphological Distribution in Micro-Injected Polypropylene Parts in the Presence of β-Nucleating Agent

Micro-injection molding is attracting much attention nowadays. Characterization of the morphological distribution in parts prepared by micro-injection molding is thus of growing importance. The morphological features of micro-parts may strongly differ from those of the macro-parts prepared by conventional injection molding, resulting in specific physical properties. In the present study, β-nucleated isotactic polypropylene micro-parts (μPPB) with 200 μm thickness, as well as macro-parts (PPB) with 2000 μm thickness, were prepared. Polarized light microscopy (PLM), scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and wide-angle X-ray diffraction (WAXD) were used to investigate their morphological features. The results show that the morphology distribution in μPPB had many differences from that of the PPB. The one-dimensional WAXD and DSC analysis showed similar results; the degree of crystallinity of the μPPB was higher than that of the PPB. However, the content of β-crystals of μPPB was lower than that of the PPB. This can be explained by the restraining effect for the formation of β-crystals in β-nucleated isotactic polypropylene (iPP) under the strong shear field. The through-the thickness-morphology of both μPPB and PPB exhibited a “skin-core” structure from PLM observations, but the former had a large fraction of shear layer in comparison to the latter implied. The SEM observations showed that the shear layer of μPPB consisted of a highly oriented shish-kebab structure, while that of the core layer consisted of deformed spherulites structure. The two-dimensional WAXD pattern of the core layer of PPB, showing full Debye rings, indicated an overall random orientation of the iPP chains, while the arcing indicated a pronounced orientation in the shear layer. The more pronounced arcing of the μPPB indicated a more pronounced orientation.     

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%.     

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.     

Effect of β-Nucleating Agent on the Crystallization,Mechanical Properties,and Heat Resistance of Injection-Molded Isotactic Polypropylene

Injection-molded β-isotactic polypropylene (β-iPP) was prepared with a commercial β-nucleating agent (NT-A). The effect of NT-A on the crystallization, mechanical properties, and heat resistance of β-iPP was investigated by differential scanning calorimetry (DSC), wide-angle X-ray diffraction (WAXD), polarized light microscopy (PLM), and mechanical and heat deflection tests. DSC and WAXD analysis showed that the content of β-crystals in the nucleated iPP was higher than that of pure iPP, and the content of β-crystals of the core was higher than that of the skin. PLM observations showed that injection-molded iPP had an obvious skin-core structure. NT-A induced abundant β-crystals and resulted in small spherulites which improved the Izod notched impact strength. When the content of NT-A was 0.075wt%, the Izod notched impact strength reached a maximum, 2.6 times more than that of pure iPP. The heat distortion temperature was also improved by NT-A.     

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.     

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.     

The Morphology and Mechanical Properties of Isotactic Polypropylene Injection-Molded Samples with the Presence of β-Nucleation Agent and Periodical Shear Field

The pressure vibration injection molding (PVIM) method was used to prepare β-nucleated isotactic polypropylene samples (PVIM β-iPP samples); a relatively low, periodical shear was imposed on the polymer melt in the mold at the filling and packing stages. The crystal structures and crystal orientation of the PVIM β-iPP samples were investigated by polarizing light microscopy (PLM), scanning electron microscopy (SEM), and synchrotron two-dimensional wide-angle X-ray diffraction (2D-WAXD). The PLM observations indicated that a cylindrite layer, rather than the transition layer, was found in PVIM β-iPP samples, which is different from the conventional injection-molded (CIM) samples. In addition, the thickness of the oriented layer of the PVIM samples was obviously greater than that of the CIM samples. The SEM observations demonstrated that a large amount of shish-kebab structures appeared in the shear layer of the PVIM β-iPP samples; at the same time, numerous β-spherulites were formed in the core layer. The 2D-WAXD data indicated that orientation homogeneity, to some degree, could be obtained by the periodical shear during PVIM. As a result, the above-mentioned morphology of the PVIM β-iPP samples leads to potentially useful prominent reinforcement and toughening of the material.     

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.     

Suppression of the Skin-Core Structure of Injection-Molded Polypropylene Part: Role of Balance Effect Caused by the Incorporation of Glass Fiber

The skin-core hierarchy structure of isotactic polypropylene (iPP) injection-molded parts was successfully suppressed by the introduction of glass fibers (GFs) as a result of the “balance effect.” The pure iPP presents a large fraction of spherulitic core layer, while the thickness of the core layer of the iPP/GF composites was greatly thinner. For pure iPP, the morphology can be divided into three regions along the thickness direction: skin layer, shear layer, and core layer. However, the morphology of the sample with 7 wt% GF was so homogenized that it could not be roughly divided into the three regions. Furthermore, the area of the shear layer becomes larger with increasing GF content. It was full of shish-kebab-like cylindrite structures. These results indicated that GF can homogenize the gradient of shear stress perpendicular to the flow direction. It was confirmed that the GF could be used to stabilize the shear-induced nuclei, especially in the core region, and resulted in the enhanced crystallinity of the β-form. Based on our investigation, a schematic model was proposed to interpret the “balance effect” of GF on suppression of the skin-core structure.     

Confined Crystallization in Polymer Blends: DSC Studies of the Behavior and Kinetics of Isothermal Crystallization of Polypropylene in Poly(cis-butadiene) Rubber Blends

Thermal properties of polypropylene with poly(cis-butadiene) rubber (iPP/PcBR) blends have been measured by differential scanning calorimetry (DSC), and the melting point T_m, crystallization temperature T_c, enthalpy Δ H (melting enthalpies and crystalline enthalpies), and equilibrium melting point T⁰ _m have been measured and calculated. The variation of T_m, T_c, Δ H and T⁰ _m with composition in the blends was discussed, showing that an interaction between phases is present in iPP/PcBR blends. The degree of supercooling characterizing the interaction between two phases in the blends and the crystallizability of the blends which bears a relationship to the composition of the blends was discussed. The kinetics of isothermal crystallization of the crystalline phase in iPP/PcBR blends was studied in terms of the Avrami equation, and the Avrami exponent n and velocity constant K were obtained. The Avrami exponent n is between 3 and 2, meaning that iPP has a thermal nucleation with two dimensional growths. The variation of the Avrami exponent n, velocity constant K, and crystallization rate G bear a relation to the composition of the blends, n increases with increasing content ofPcBR. K also increased with increasing content of PcBR. All of the K for the blends are greater than for pure iPP. The crystallization rate G (t_1/2) depends on the compositions in the blends; all G of the blends are greater than for iPP.     

Microstructural Evolution and Its Effect on Mechanical Properties of Isotactic Polypropylene by Shear Plastic Deformation at Elevated Temperatures

Isotactic polypropylene (iPP) was plastically shear deformed by equal channel angular extrusion (ECAE) at extrusion temperatures varied from 45 to 125°C (25 mm/min). The evolutions of morphology and crystal orientation were studied by reflected optical microscopy (ROM), scanning electron microscopy (SEM), and X-ray diffraction. It was found that the original spherulites were deformed into nearly ellipsoids with their long axis tilted at an angle away from the flow direction. Azimuthal scanning results revealed that two preferred crystal orientations were formed after ECAE. The crystal plasticity was activated by increasing the extrusion temperature, followed by fast rotation of crystallites toward the shear direction. The thermal mechanical analysis (TMA) indicated that low extrusion temperature was favorable to fix the molecular orientation. The iPP samples processed at the investigated temperatures displayed a significant increase in the impact strength, especially for those extruded at 45°C and 65°C. The tensile results revealed a greater elongation at break in the samples deformed at low temperatures (45°C and 65°C) but not in those deformed at high temperatures (85°C or above).     

Synthesis and Effect of Ammonium 2,2′-Methylene-bis-(4,6-di-t-Butylphenylene) Phosphate as Nucleating Agent of Poly(Propylene)

A nonmetallic organophosphate salt, ammonium 2,2′- methylene-bis-(4,6-di-t-butylphenylene) phosphates (An), was synthesized via a simple method, and its application in iPP as a nucleating agent was investigated. Differential scanning calorimetry (DSC) result showed the melting temperature of An was 262°C, and SEM (scanning electron microscopy) observations indicated that its crystallization morphology was lamellar shape with a quite smooth surface. The crystallization behavior of nucleated isotactic poly(propylene) (iPP) containing An demonstrated that An can effectively raise the crystallization peak temperature and reduce the spherulite size, resulting in obviously improved strength and transparency. The tensile and flexural strength of iPP nucleated with An was increased by 11% and 32%, respectively. The haze value of iPP/An was decreased from 36.7% to 15.5%. These results revealed that this organophosphate ammonium salt can be used as an effective nucleating agent of iPP and provides a new organophosphate salt type nucleating agent for polymers.     

Mechanical Properties and Crystallization Behavior of Polycarbonate/Polypropylene Blends

The mechanical properties, morphology, and crystallization behavior of polycarbonate (PC)/polypropylene (PP) blends, with and without compatibilizer, were studied by tensile and impact tests, scanning electron microscopy (SEM), X-ray diffraction (XRD), and differential scanning calorimetry (DSC). The tensile and impact strengths of PC/PP blends decreased with increasing the PP content due to poor compatibility between the two phases. But the addition of compatibilizer improved the mechanical properties of the PC/PP blends, and the maximum value of the mechanical properties, such as tensile and impact strengths of PC/PP (80/20 wt%) blends, were obtained when the compatibilizer was used at the amount of 4 phr. The SEM indicated that the compatibility and interfacial adhesion between PC and PP phases were enhanced. DSC results that showed the crystallization and melting peak temperatures of PP increased with the increase of the PP content, which indicated that the amorphous PC affected the crystallization behavior. However, both the PC and compatibilizer had little effect on the crystallinity of PP in PC/PP blends based on both the DSC and XRD patterns.     

The Crystallization and Morphology of Isotactic Polypropylene Nucleated by Magnesium Sulfate Whiskers Surface Modified by Pimelic Acid

Pimelic acid (PA) was used to modify the surface of magnesium sulfate whiskers (M-HOS). The treated M-HOS and its effects as a function of concentration on the crystallization and morphology of isotactic polypropylene (iPP) were investigated. Scanning electron microscopy (SEM), wide-angle X-ray diffraction (WAXD), thermogravimetic analysis (TGA), and Fourier transform infrared spectroscopy (FTIR) revealed that PA reacted with M-HOS and formed magnesium pimelate on the surface after the reaction. The results of differential scanning calorimetry (DSC) and polarized light microscopy (PLM) showed that the treated M-HOS had the ability to induce β-spherulites, increase the crystallization temperature and decrease the size of spherulites in iPP. It was the most effective to form β-spherulites when the content of PA treated M-HOS was 5 wt%.     

Correlation of Oscillation Cycles and Crystallization in HDPE Blends with Small Amounts of HMWPE Prepared by Dynamic-Packing Injection Molding

The effect of oscillation cycles on crystal morphology was investigated for high-density polyethylene (HDPE) in blends with 4 wt% high molecular weight polyethylene (HMWPE) (labeled B4) in samples prepared through dynamic-packing injection molding (DPIM). With the aid of differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and transmission electron microscopy (TEM), a weblike shish-kebab morphology that markedly increased stiffness and toughness was found at a specific oscillation cycle. The DSC and SEM results showed that crystal morphology was altered with changes in the oscillation cycle. The SEM and TEM results showed that a much better weblike shish-kebab structure, in which most of the lamellae connect different columns compared with conventional shish-kebabs, was formed in the B4 samples when the oscillation cycle was 10s. These results show that a proper oscillation cycle favors the improvement of crystal structures in HDPE blends induced by a small amount of HMWPE.     

Preparation,Morphology and Properties of Poly(Trimethylene Terephthalate)/Thermoplastic Polyester Elastomer Blends

Poly(trimethylene terephthalate)(PTT)/thermoplastic polyester elastomer (TPEE) blends were prepared and their miscibility, crystallization and melting behaviors, phase morphology, dynamic mechanical behavior, rheology behavior, spherulites morphology, and mechanical properties were investigated by differential scanning calorimetry (DSC), scanning electron microscopy (SEM), dynamic mechanical analysis (DMA), parallel-plate rotational rheometry, polarized optical microscopy (POM), wide angle X-ray diffraction (WAXD), universal tensile tester and impact tester, respectively. The results suggested that PTT and TPEE were partially miscible in the amorphous state, the TPEE rich phase was dispersed uniformly in the solid matrix with a size smaller than 2 μm, and the glass transition temperatures of the blends decreased with increasing TPEE content. The TPEE component had a good effect on toughening the PTT without depressing the tensile strength. The blends had improved melt viscosities for processing. When the blends crystallized from the melt state, the onset crystallization temperature decreased, but they had a faster crystallization rate at low temperatures. All the blends’ melts exhibited a predominantly viscous behavior rather than an elastic behavior, but the melt elasticity increased with increasing TPEE content. When the blends crystallized from the melt, the PTT component could form spherulites but their morphology was imperfect with a small size. The blends had larger storage moduli at low temperatures than that of pure PTT.     

Effect of Malonic Acid Treatment on Crystal Structure,Melting Behavior,Morphology, and Mechanical Properties of Isotactic Polypropylene/Nano-CaCO3 Composites

The influence of malonic acid (MA) treatment of nano-calcium carbonate (CaCO₃) on the crystallization, morphology, and mechanical properties of isotactic polypropylene (iPP)/nano-CaCO₃ composites have been studied. The results of differential scanning calorimetry (DSC), wide angle X-ray diffraction (WAXD) and polarized light microscopy (PLM) show that untreated nano-CaCO₃ facilitates the formation of α phase, while MA treated nano-CaCO₃ increases the relative content of β phase of iPP dramatically. The results of scanning electron microscopy (SEM) show that MA treated nano-CaCO₃ has better dispersion in the matrix than the untreated one. The toughness of PP/MA treated nano-CaCO₃ composite is improved drastically. When 2.5 wt% MA treated nano-CaCO₃ is added, the Izod notched impact strength reaches its maximum, which is 2.89 times greater than that of the pure iPP.     

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     

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.     

Isothermal lamellar thickening in blends of linear and low-density polyethylene

Polyethylene blends were studied by differential scanning calorimetry (DSC) and transmission electron microscopy (TEM). Binary blends of commercial linear polyethylene (LPE) with two low-density polyethylenes (LDPEs) of melt indexes, about 20 and about 0.27 g/10 minutes, were investigated. The blends, with 10% and 50% LPE contents, and the pure LPE were isothermally crystallized at 124°C for up to 48 h under solid-liquid phase segregation conditions. Double melting endotherms were obtained for the blends. Results show that, despite differences in crystallization kinetics between both types of blends, the same depression in the LPE melting temperature and approximately the same LPE crystal thicknesses were found for the blend compositions. In addition, the extent of occurrence of lamellar thickening in LPE during crystallization is a function of its content in the blend.