Fractionated crystallization of α‐ and β‐nucleated polypropylene droplets

A layer multiplying coextrusion process was used to produce multilayered polypropylene/polystyrene (PP/PS) films with various nucleating agents. When heated into the melt, the thin PP layers broke up into submicron PP droplets that exhibited fractionated crystallization. If the initial PP layers were 20 nm or less, the resulting droplets exhibited exclusively homogeneous nucleation. If a nucleating agent was added, the systematic departure from homogeneous nucleation provided insight into the nature of the heterogeneous nucleation. In this study, we used thermal analysis, atomic force microscopy (AFM), and wide angle X‐Ray scattering (WAXS) to examine the effect of two nucleating agents. We confirmed with WAXS and AFM that a soluble sorbitol nucleating agent for the PP α‐form operates in three concentration regimes as proposed in a previous study. Morphologically, homogeneous nucleation of the submicron droplets produced a granular texture. The correlation length from small‐angle X‐Ray scattering (SAXS) suggested that the grains contained 1–3 mesophase domains. Drawing on classical nucleation theory, the critical size nucleus of an individual mesophase domain was estimated to be about 2 nm³, which was considerably smaller than the mesophase domain. This pointed to mesophase crystallization that included the processes of nucleation and growth. Additional experiments were performed with nucleating agents for the PP β‐form. However, they were not effective in nucleating crystallization of the droplets, presumably because they were essentially insoluble in PP and the nucleating particles were too large to be accommodated in the PP droplets. © 2010 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys, 2011     

Fractionated crystallization of polypropylene droplets produced by nanolayer breakup

Layer‐multiplying coextrusion was used to fabricate assemblies of 257 layers, in which polypropylene (PP) nanolayers alternated with thicker polystyrene (PS) layers. The PP layer thickness was varied from 12 to 200 nm. When the assembly was heated into the melt, interfacial instability‐driven breakup of the thin PP layers produced a dispersion of PP particles in a PS matrix. Particle size analysis indicated that breakup of PP microlayers produced a bimodal particle size distribution. A population of submicron particles formed because of the Rayleigh instability, and a second population of large particles formed by relaxation. Breakup of 12‐nm layers resulted in primarily submicron particles. The fraction of PP as submicron particles dropped dramatically as the layer thickness increased to 40 nm. The particle dispersion was characterized by thermal analysis and wide angle X‐ray diffraction. Fractionated crystallization gave rise to four crystallization exotherms at 40, 60, 85, and 100 °C. The exotherm at 40 °C was identified with homogeneous nucleation of the submicron particles in the smectic form. Exotherms at higher temperatures represented fractionated crystallization of the large micron‐sized particles in the PP α‐form. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 1138–1151, 2007     

Annealing behavior of the novel morphology of poly(butylene succinate) lath‐shaped single crystals

Lamellar single crystals of poly(butylene succinate) (PBS) with novel morphologies were prepared from a chloroform/methanol solution by self‐seeding methods. Crystal structures and morphologies were investigated by means of atomic force microscopy (AFM). Lath‐shaped crystal and hexagonal‐shaped crystals coexist in one PBS single crystal and this has a lamellar thickness of around 5–6 nm as determined by AFM. The thickening of lamellae from 5–6 to 7–9 nm occurred during heating from 41 to 84 °C. In situ temperature‐controlled AFM observations demonstrated that the lath‐shaped crystal sections melted first and then the hexagonal sections while the edge of the single crystals remained regular during annealing. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 1492–1496, 2009     

Crystalline structure and morphology of microphases in compatible mixtures of poly(tetrahydrofuran‐methyl methacrylate) diblock copolymer and polytetrahydrofuran

The crystalline structure and morphology of compatible mixtures of poly(tetrahydrofuran‐methyl methacrylate) diblock copolymers (PTHF‐b‐PMMA) with a polytetrahydrofuran homopolymer (PTHF) were studied with synchrotron X‐rays. Wide‐angle diffraction was used to study the crystalline structures in a confined lamellar region with a PTHF thickness ranging from 12.2 to 19.5 nm, and in a PTHF matrix with an interface distance between the PMMA cylinders ranging from 17 to 22 nm. As the above thickness values are around the long period (ca. 17 nm) of PTHF homopolymer under the crystallization condition used, the crystalline structure has been found to be very sensitive to the average thickness of the PTHF phase. The changes in the diffraction patterns with changing PTHF homopolymer content suggested a chain folding model in confined PTHF lamellae with the PTHF fiber axes being perpendicular to the thick PTHF lamella. In the case of hexagonally packed cylindrical PMMA microdomains with an interface distance ranging from 12 to 16 nm, the effects of PMMA cylinders on the crystallization morphology of PTHF in the PTHF matrix, and the effects of the PTHF crystallization on the hexagonally packed structure of PMMA cylinders were also studied. It is shown that only when the interdistance of two neighboring PMMA cylinders is comparable with the long period of the pure PTHF homopolymer, ordered PTHF stacks can be formed in the PTHF matrix. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 779–792, 1999     

Thin film confinement reduces compatibility in symmetric ternary block copolymer/homopolymer blends

The thin film phase behavior of ternary blends consisting of symmetric poly(styrene) (PS)-b-poly(dimethylsiloxane)(PDMS), PS, and PDMS was investigated using X-ray reflectivity (XRR) and atomic force microscopy (AFM). This system is strongly segregated, and the homopolymers are approximately the same length as the corresponding blocks of the copolymer. The XRR and AFM data are used to quantify changes in domain spacing (L) and morphology evolution with increasing homopolymer content (Φ _H). In 100 nm thick films, from Φ _H = 0 to 0.20, the system maintains a perfect parallel lamellar structure and domains swell as predicted based on theory; however, from Φ _H = 0.30 to 0.50, a morphology transition to a “dot pattern” morphology (tentatively identified as perforated lamellae) and mixed morphologies were observed before macrophase separation. In thicker films, dot patterns were observed for a broad range of Φ _H before macrophase separation. The absence of the bicontinuous microemulsion phase reported for bulk blends and thin films of perpendicular lamellae and the presence of dot patterns/perforated lamellae are attributed to preferential migration of the PDMS homopolymer to the wetting layers located at the substrate and free air interfaces, which leads to an asymmetric composition within the film and morphology transition. © 2018 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2018 , 56, 1443–1451     

Nanostructure and crystallization phenomena in multilayered films of alternating iPP and PA6 semicrystalline polymers

The present work is concerned with the study of the crystalline morphology and the nanostructure of a multilayered system of two alternating immiscible semicrystalline polymers: isotactic polypropylene (iPP) and polyamide 6 (PA6). Films with a volume ratio of 70/30 were prepared by means of layer multiplying coextrusion. Contrary to previous experiments, performed with semicrystalline/amorphous and amorphous/amorphous nanolayered systems, the studied iPP/PA6 film does not exhibit a well defined maximum in the USAXS patterns. This result accounts for an irregular layered structure, as further confirmed by means of TEM images. Nevertheless, such a layered assembly still influences the crystallization behaviour of both constituent polymers. On the one hand, the crystallization of PA6 within the multilayered material is substantially hindered as evidenced by its weak scattering intensity. Real time studies as a function of temperature undoubtedly detect the presence of a WAXS peak and a SAXS maximum associated to PA6 above the melting temperature of iPP. Room temperature AFM studies also confirm the occurrence of crystalline structures within the PA6 layers. On the other hand, SAXS and WAXS measurements at room temperature reveal the occurrence of an oriented lamellar morphology within the iPP layers bearing uniaxial symmetry around an axis perpendicular to the layers surface. Results show that the crystalline molecular chains are placed mainly parallel to the layer surfaces forming edge-on lamellae. Moreover, X-ray scattering results are in agreement with the occurrence of two populations of lamellae, both edge-on and perpendicular to each other, in agreement with the crosshatched morphology observed by AFM.     

Cavitation and morphological changes in polypropylene deformed at elevated temperatures

Polypropylene (PP) thick films were subjected to tensile drawing at various temperatures from the room temperature to 100 °C. Morphological alterations during drawing were followed by wide‐angle X‐ray scattering, small‐angle X‐ray scattering, and scanning electron microscopy (SEM) of sectioned and etched samples, volume strain measurement, and light transparency measurement at various level of strain. The morphological observations were paralleled with stress–strain determination. Samples drawn at 25 and 40 °C undergo severe cavitation contributing to their volume increase up to 90–95%. The volume increase contributes greatly to the engineering strain. PP drawn at 70 and 100 °C does not cavitate. At the strain up to 1.2, a high lamellae orientation is observed in SEM, whereas the 2D WAXS patterns show in contrary circular diffraction rings indicating low orientation of crystals. The rotation of lamellae toward drawing direction is associated with reverse rotation of chains in crystals due to fine chain slips. These two rotations in opposite directions counterbalance resulting in a much weaker crystal orientation than expected from the SEM images. Noncavitating samples retain their translucency up to a high strain. © 2010 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 48: 1271–1280, 2010     

Effect of film thickness on morphological evolution in dewetting and crystallization of polystyrene/poly(ε-caprolactone) blend films

In this Article, the morphological evolution in the blend thin film of polystyrene (PS)/poly(ε-caprolactone) (PCL) was investigated via mainly AFM. It was found that an enriched two-layer structure with PS at the upper layer and PCL at the bottom layer was formed during spinning coating. By changing the solution concentration, different kinds of crystal morphologies, such as finger-like, dendritic, and spherulitic-like, could be obtained at the bottom PCL layer. These different initial states led to the morphological evolution processes to be quite different from each other, so the phase separation, dewetting, and crystalline morphology of PS/PCL blend films as a function of time were studied. It was interesting to find that the morphological evolution of PS at the upper layer was largely dependent on the film thickness. For the ultrathin (15 nm) blend film, a liquid-solid/liquid-liquid dewetting-wetting process was observed, forming ribbons that rupture into discrete circular PS islands on voronoi finger-like PCL crystal. For the thick (30 nm) blend film, the liquid-liquid dewetting of the upper PS layer from the underlying adsorbed PCL layer was found, forming interconnected rim structures that rupture into discrete circular PS islands embedded in the single lamellar PCL dendritic crystal due to Rayleigh instability. For the thicker (60 nm) blend film, a two-step liquid-liquid dewetting process with regular holes decorated with dendritic PCL crystal at early annealing stage and small holes decorated with spherulite-like PCL crystal among the early dewetting holes at later annealing stage was observed. The mechanism of this unusual morphological evolution process was discussed on the basis of the entropy effect and annealing-induced phase separation.     

Surface and interface morphology of polystyrene/poly(methyl methacrylate) thin‐film blends and bilayers

The surface and interface morphologies of polystyrene (PS)/poly(methyl methacrylate) (PMMA) thin‐film blends and bilayers were investigated by means of atomic force microscopy (AFM) and X‐ray photoelectron spectroscopy. Spin‐coating a drop of a PS solution directly onto a PMMA bottom layer from a common solvent for both polymers yielded lateral domains that exhibited a well‐defined topographical structure. Two common solvents were used in this study. The structure of the films changed progressively as the concentration of the PS solution was varied. The formation of the blend morphology could be explained by the difference in the solubility of the two polymers in the solvent and the dewetting of PS‐rich domains from the PMMA‐rich phase. Films of the PS/PMMA blend and bilayer were annealed at temperatures above their glass‐transition temperatures for up to 70 h. All samples investigated with AFM were covered with PS droplets of various size distributions. Moreover, we investigated the evolution of the annealed PS/PMMA thin‐film blend and bilayer and gave a proper explanation for the formation of a relatively complicated interface inside a larger PS droplet. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 9–21, 2006     

Flat-on lamellae in spin-coated, stable films of poly(propylene azelate)

Thin films (5-500 nm thick) of the linear aliphatic polyester (3,7) poly(propylene azelate) (PPAz) were prepared by spin-coating of CHCl(3) polymer solutions with different polymer concentrations. The morphology and structure of the spin-coated thin films were investigated by atomic force microscopy (AFM) and by grazing incidence wide-angle X-ray scattering (GIWAXS) techniques. AFM revealed the continuous nature of the flat, spherulitic films which are stable against dewetting even for polymer coatings as thin as 15 nm. GIWAXS patterns revealed a high crystal orientation of the films. A sharp reflection on the meridian whose spacing is related to the polymer chain unit length (c-axis) supports the presence of flat-on lamellae morphology in the whole range of film thicknesses investigated. The flat-on lamellae morphology is also supported by AFM images. A triclinic unit cell with the c*-axis perpendicular to the substrate is proposed for PPAz. The repulsion of the long aliphatic spacer by the Si-substrate is invoked as the main reason for the flat-on morphology observed.     

The influence of nano‐PS particle on structure evolution and electrical properties of PP/PS

The polypropylene‐g‐polystyrene (PP‐g‐PS) copolymers with different grafting ratios are used as compatibilizers to control the size of polystyrene (PS) particles at nanometer scale in polypropylene (PP) matrix. Then the PP/PS insulating nanocomposites (containing 10 wt % PS calculated from PS and PP‐g‐PS) are manufactured. With the increase in grafting ratio of PP‐g‐PS, the size of PS particle is reduced and the interfacial adhesion is enhanced. Meanwhile, the dielectric properties, DC breakdown strength and volume resistivity are increased with the decreasing of PS particle size. The spherulite size of PP is decreased and the boundary between crystals and amorphous regions is blurred or even disappears due to the presence of PS nanoparticles. This evolution of PP structure is attributed to the serious entanglements of PP and PS molecular chains. Finally, the correlation between morphological structure and electrical properties is ultimately established based on the in‐depth understanding of the molecular chain movement, crystal structure, and phase morphology. © 2018 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2018 , 56, 706–717     

On the origin of the “core‐free” morphology in microinjection‐molded HDPE

This study investigates the morphology of a high‐density polyethylene processed with microinjection molding. Previous work pointed out that a “core‐free” morphology exists for a micropart (150‐μm thick), contrasting with the well‐known “skin‐core” morphology of a conventional part (1.5‐mm thick). Local analyses are now conducted in every structural layer of these samples. Transmission electron microscopy observations reveal highly oriented crystalline lamellae perpendicular to the flow direction in the micropart. Image analysis also shows that lamellae are thinner. Wide‐angle X‐ray diffraction measurements using a microfocused beam highlight that highly oriented shish–kebab morphologies are found through the micropart thickness, with corresponding orientation function close to 0.8. For the macropart, quiescent crystallized morphologies are found with few oriented structures. Finally, the morphology within the micropart is more homogeneous, but the crystalline structures created are disturbed due to the combined effects of flow‐induced crystallization and thermal crystallization during processing. © 2011 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 49: 1470–1478, 2011     

Fibrils separated from polyacrylonitrile fiber by ultrasonic etching in dimethylsulphoxide solution

A novel method for the separation of polyacrylonitrile (PAN) fibrils from fibers by ultrasonic etching in a 90 wt % aqueous dimethylsulphoxide (DMSO) solution at 75 °C ± 2 °C for 6 h with a frequency of 40 kHz is demonstrated. These fibrils with a diameter of about 450 nm were systematically investigated by field emission scanning electron microscopy (FESEM), high resolution transmission electron microscopy (HRTEM), and wide‐angle X‐ray diffraction (WAXD). It was found that the fibrils consisted of microfibrils with about 200 nm diameter, including periodic lamellae with thickness of 30–45 nm perpendicular to the fiber axis. The PAN fiber crystallinity and crystal size slightly decreased under the ultrasonic etching. © 2010 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 48: 617–619, 2010     

Formation and transformation of smectic polypropylene nanodroplets

A dispersion of isotactic polypropylene (PP) nanoparticles was produced by interfacially‐driven breakup of PP nanolayers. Layer‐multiplying coextrusion was used to fabricate an assembly of 257 alternating PP nanolayers about 12 nm thick sandwiched between thicker polystyrene (PS) layers. Characterization by thermal analysis and wide‐angle X‐ray diffraction (WAXD) confirmed that PP crystallized primarily in the smectic form when confined as nanolayers. When the layered assembly was heated into the melt, the PP nanolayers broke up to form a dispersion of PP droplets in a PS matrix. After solidification, particle size analysis revealed that 90% of the PP was present as 30 nm nanoparticles. The particles were small enough and numerous enough that most did not contain a primary nucleus. When cooled from melt at 10 °C min^?1, the droplets crystallized by homogeneous nucleation at 40 °C. The droplets were found to be in the smectic form by WAXD. Because crystallization occurred below the temperature of the smectic to α‐form transformation, the intermediate smectic form was stable and did not convert to the α‐form until heated above 70 °C. This result provided direct evidence for an intermediate smectic phase in the process whereby homogeneous nucleation leads to α‐form crystals in confined nanoparticles. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 1795–1803, 2006     

Structure of ultrathin polyethylene layers in multilayer films

The crystalline structures of “microlayer” and “nanolayer” polyethylene have been examined in coextruded films comprised of alternating layers of high-density polyethylene and polystyrene. Transmission electron microscopy (TEM), small-angle x-ray scattering (SAXS), and wide-angle x-ray scattering (WAXS) reveal that microlayer polyethylene, where the layer thickness is on the order of several microns, crystallizes with the normal unoriented lamellar morphology. In nanolayer films, where the film thickness of tens of nanometers is on the size scale of molecular dimensions, lamellae are oriented with the long axes perpendicular to the extrusion direction in a row-nucleated morphology similar to structures described in the literature. The lamellae are partially twisted about the long axes. The preferred twist angles of ±40° orient the lamellar surfaces normal to the layer surface. The row-nucleated morphology imparts highly anisotropic mechanical properties to the nanolayer polyethylene.     

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

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

Submicron films prepared from aqueous dispersions of nanoscale polymer crystals

Thin and ultrathin films of polyethylene of variable thickness are obtained from aqueous dispersions of prefabricated nanoscale crystals by spin‐coating. Continuous films with a thickness of only 15 nm, up to 220 nm, homogeneous over hundreds of μm, or assembled discontinuous monolayers of flat‐on lamella particles were prepared, depending on the solids content of the dispersion employed, as revealed by AFM and TEM. The morphology of melt‐recrystallized films was not affected by the surfactant present. Homogeneous continuous films without undesirable dewetting were retained upon melting and recrystallization of the films upon cooling, composed of polygonal spherulites for a thicker film (220 nm), randomly grown edge‐on lamella for a 40 nm film, and dominant flat‐on lamella for a 15 nm thick film. Annealing below T_m resulted in lamella thickening, without changes of crystal orientation or structure of the particle assemblies for discontinuous monolayers. Surfactant adsorbed to the nanocrystals in the aqueous dispersion desorbs at least partially during formation of the nascent films, and upon annealing below the melting point surfactant migrates to the film‐air interface to form aggregates, which can be removed by rinsing, during which the film stays intact and structurally unaltered as revealed, amongst others, by water contact angles. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 6420–6432, 2009     

Crystalline β‐structure of PHBV grown epitaxially on silicate layers of MMT

The poly(3‐hydroxybutyrate‐co‐3‐hydroxyvalerate) (PHBV)/montmorillonite(MMT) nanocomposites were investigated by wide‐angle X‐ray scattering (WAXS). The aim of the investigation was solution intercalation of MMT with PHBV. Beside the usual orthorhombic unit cell, a stable pseudohexagonal β‐structure of PHBV was obtained. Well known β‐structure has one common WAXS reflection (d = 0.480 nm), which corresponds to the mean distance of PHBV chains in the pseudohexagonal structure. The new β‐structure has two diffraction peaks in the WAXS pattern. It is a three‐dimensionally ordered crystalline structure oriented in parallel with the silica layers of MMT. The new polymorphic form is supposed to be growing on the layers of MMT. Its layers serve as primary nucleation centers for epitaxial growth of the β‐structure. After annealing, this polymorphic form of PHBV disappears and it is transformed into the more stable α‐form leading to an enhanced total crystallinity of the polymer comprised in the nanocomposite. © 2009 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 47: 751–755, 2009     

ω-substituted long chain alkylphosphonic acids – their synthesis and deposition on metal oxides and subsequent functional group conversion of the deposited compounds

The crystal structure and the surface of alumina layers on silicon wafers were investigated by means of GIWAXS, WAXS, and AFM. Self-assembled monolayers of ω-substituted long-chain alkylphosphonic acids were deposited on alumina and the layer thickness and homogeneity were determined by ellipsometry revealing a dependency of thickness and homogeneity on the nature of the substituent. During the adsorption process surface etching by the phosphonic acid was observed causing an increase in surface roughness. Furthermore, ex post functional group conversions were carried out yielding surface bound azides and rhodanides.     

Evaluation of Morphology and Deformation Micromechanisms in Multilayered PP/PS Films: An Electron Microscopy Study

Nanostructured polymers and ultra-thin polymer layers are used more and more in technical applications like nanotechnology and microelectronics. Therefore, it is really important to understand the size-scale dependent properties as bulk polymers become thinner and more two-dimensional. Here the morphology as well as the macroscopic and the microscopic deformation behaviour of multilayered films of polypropylene (PP) and polystyrene (PS) have been investigated. For investigation different microscopic techniques and tensile testing were used. The films were prepared by multilayer coextrusion, whereas the composition of PP and PS and the film thickness – and therefore the thickness of each layer – varied. The thinnest calculated thickness of a single layer was about 5 nm. It is shown that the PP/PS films consist usually of homogeneous layers with only few defects. As the composition of PP/PS deviates strongly from 50/50 or the films get thinner the number of defects increases and the layered system turns to irregular lamellar system. In macroscopic tensile tests the small PS layers affect the elongation at break enormously: Most of the samples are brittle. For the films with a composition of PP/PS 90/10 and the film PP/PS 70/30 with a film thickness of 25 µm an elongation at break of 66% and higher could be reached. Transmission electron microscopy on these samples shows that the layers are characterized by plastic yielding in local deformation zones.