Extended-chain crystals. II. Crystallization of polyethylene under elevated pressure

A report on crystallization of polyethylene at elevated pressures to an extended-chain morphology is presented. The crystals have been characterized by electron microscopy and density determination. Pressure, supercooling (temperature), and crystallization time have been varied to find the best conditions for production of perfect crystals. At 10–30°C supercooling completely crystallized polyethylene was obtained between 4.5 and 7 kb crystallization pressure in 1–8 hr. Analysis of fracture surfaces of samples crystallized for different lengths of time shows an increase in size and number of crystal lamellae and an improvement of extended chain crystals in the early stages of crystallization. A further improvement of the less well crystallized material between the lamellae occurs after 15 min of crystallization time.     

Extended-chain crystals. VI. Annealing of polyethylene under elevated pressure

Polyethylene crystals of different degrees of perfection were annealed at 5.1 kb pressure for 20 hr at various temperatures and analyzed by electron microscopy, thermal analysis, and density determination. No annealing took place until the temperature was close to the melting point of the starting material. Up to 235°C increasing solidstate annealing was observed. Mixed crystals of up to 0.989 g/cm³ density and 1500 Å thickness in the chain direction could be produced. At slightly higher temperature recrystallization to extended-chain crystals rather than annealing occurred. The annealing process at atmospheric pressure seems to be similar in nature, but takes much longer for comparable perfection. From a comparison of annealing and crystallization it is concluded that polymer crystallization goes through a stage of internally imperfect order during which most of the observed chain extension occurs. Estimates of this outer imperfect layer of a growing crystal place its depth at 30,000 Å.     

Extended-chain crystals. III. Size distribution of polyethylene crystals grown under elevated pressure

Extended-chain crystals of high molecular weight polymethylene, a polyethylene with a broad molecular weight distribution, and three fractions of polyethylene were grown from the melt under elevated pressure. Comparison of the crystal size distribution in the molecular chain direction (measured on fracture surfaces by electron microscopy) with the molecular weight distribution (measured by gel-permeation chromatography) gave the following results. Up to molecular weight 10,000 all samples showed eutectic separation into fully extended chain crystals of narrow molecular weight distribution. Above molecular weight 10,000 mixed crystals were formed. Under the chosen crystallization conditions larger chain extension was achieved with higher molecular weights. However, an increase in molecular weight by a factor of 1000 led only to a tenfold increase in chain extension. These facts are discussed in the light of a proposed mechanism of crystal growth.     

Extended-chain crystals. IV. Melting under equilibrium conditions

Dilatometric melting experiments were performed on an extended-chain crystalline polyethylene with a broad molecular weight distribution and on four samples crystallized from fractionated polyethylenes. The melting curves were compared with computer calculations based on the assumption of eutectic separation. For the fraction of lowest molecular weight, agreement between experiment and calculation was achieved. The melting behavior of all other samples indicated that only for molecular weights up to 10,000–12,000 did eutectic separation occur. The higher molecular weight portion of each sample crystallized in the form of mixed crystals. Of the experimental maximum melting-point lowering of these mixed crystals, 0.1–0.9°C is due to the lower molecular weight diluents. Another 2–3°C lowering in melting point is due to the fact that the phase diagram of polyethylene mixed crystals has a minimum.     

Extended-chain crystals. V. Thermal analysis and electron microscopy of the melting process in polyethylene

Differential thermal analysis and electron microscopy of partially molten, extended-chain polyethylene crystals, grown under elevated pressure, was performed. It could be shown that melting peaks on the low temperature side of the main melting peak are due to narrowly distributed, low molecular weight polymer segregated in extended-chain crystals. Superheating of crystals before melting increased with molecular weight and chain extension. The melting mechanism of extended chain crystals was shown to be a successive peeling off of chains which leaves the chain extension constant up to melting of the last crystal trace.     

Crystallization and melting of polyethylene under high pressure. III. Mixed crystallization of two kinds of extended-chain crystals

Thermal behaviors of extended-chain crystals of polyethylene formed during various crystallization processes and conditions under about 5000kg/cm² were studied by high-pressure dilatometry and differential scanning calorimetry. The experiments indicate that by isothermal crystallization at small undercoolings for prolonged periods, the products show two endothermic peaks in the melting region of the usual extended-chain crystals. This means of the presence of a bimodal lamellar thickness distribution in the extended-chain crystals. A phase diagram has been made for pressures up to 5000 kg/cm². The experimental results confirm the existence of two kinds of extended-chain crystals, i.e., ordinary extended-chain and highly extended-chain crystals, as suggested previously by the authors.     

Halogenation of polyethylene. I. Bromination of single crystals

It has been demonstrated that the fold surfaces of polymers can be specific towards chemical attack, if the reaction is mild and nondestructive of the fold. Bromination of suspensions of single crystals of polyethylene in carbon tetrachloride has been shown to be such a system. This chemical modification of a fold surface is a powerful means of extending the applications of the physical methods available. Several methods were used, among them DTA, DSC, infrared spectroscopy and small-angle x-ray diffraction. Experimental results from these methods lead to the following conclusions. (a) Bromination takes place preferentially at the folds and is consistent with a regular adjacent reentry fold model. (b) Annealing of these brominated crystals demonstrates the major role played by the crystal surface in this process. (c) The preparation and properties of a novel copolymer system has been demonstrated. It is felt that this copolymer system may prove a useful addition to those systems presently available.     

Thermodynamics of crystalline linear high polymers. V. Extended-chain copolymers of polyethylene

Ethylene—propylene and ethylene—butene-1 copolymers with up to 1.7 side groups per 100 carbons have been crystallized at 227°C. and under 4100–4900 atm. pressure. The resulting crystalline polymers are at least partially of extended-chain crystal morphology. Comparison with the same polymers crystallized at atmospheric pressure, which gives folded-chain crystal morphology, revealed: (1) a density higher by 0.008–0.019 g./cm.³ depending on copolymer content; (2) a similar decrease of crystallinity with side group concentration; (3) a similar decrease of the beginning of melting from 125°C. for homopolymer to 65°C. for 1.7 side groups per 100 carbons; (4) a higher (138 ± 0.8°C.) experimental maximum melting point which, in contrast, is independent of copolymer content and seems to vary only with the fraction of low molecular weight material; (5) a decreasing amount of high-melting crystals with increasing copolymer content (72–8%) and an increasing amount of low-melting crystals (27–53%) with increasing copolymer content. In addition, superheating, which reached 5.5°C. for 50°C./min. heating rates, was detected. It was concluded that high-pressure crystallization leads, at least for part of the crystals, to solid solution formation, while atmospheric pressure crystallization does not. Which mode of crystallization is achieved seems kinetically determined. Experimental techniques were dilatometry, DTA, and calorimetry.     

NMR study of polyethylene crystallization kinetics under high pressure

Crystallization of polyethylene under hydrostatic pressures of 1–4.5 kbar is directly observed using pulsed proton NMR. The rate of growth of extended-chain polyethylene crystals is measured over this pressure range and to a maximum temperature of 227°C. The observed crystallization isotherms are superimposable on a log time scale; this implies a consistent mechanism for extended-chain growth over this pressure range. Avrami coefficients for high-pressure extended-chain crystallization are determined to be 1.3–1.7. A decrease of crystal nucleus surface free energies with increasing pressure is indicated. Findings are consistent with Wunderlich's model of initial folded-chain crystallization followed immediately by chain extension. Future applications of this NMR technique are briefly considered.     

Thickening of crystals during rapid heating. I. Linear polyethylene and nylon-6

The change of long spacing in polyethylene and nylon-6 during heating at 18°C/min. was measured with an apparatus devised for rapid measurement of the small-angle x-ray diffraction. The apparatus made it possible to obtain a diffraction profile in 1.8 sec. Long spacings increased notably at high temperatures near the melting point, as has been observed during low-rate heating. However, the increase in long spacing during heating was very small in a methoxymethylated nylon-6 sample. This suggests that the increase in the long spacing at high temperature is due to the thickening of crystals. The long spacing in polyethylene samples in the vicinity of the melting point is apparently independent of thermal history.     

Fractionation of linear polyethylene during bulk crystallization under high pressure

Two linear polyethylene fractions (M_η, 11,260 and 100,000) and mixtures of these fractions have been isothermally crystallized from the melt under pressures up to 3000 atm. Characterization of individually crystallized fractions with transmission electron microscopy indicates that pressure can be used to produce a crystallite whose thickness is a measure of the chain length within it. Although the high molecular weight fraction yields spherulites containing individually varying lamellae thicknesses, the maximum thickness of each lamella is a measure of the chain length within it. Both electron micrographs and differential thermal analysis results show that crystallization of homogeneous mixtures of the high and low molecular weight fractions under high pressure results in a distinct fractionation and segregation according to molecular weight.     

The effect of pressure crystallization on structure and properties of hot-drawn polyethylene

Colloid and Polymer Science - The change of the drawing behaviour of polyethylene is studied as a function of molecular weight and crystallization pressure. The results are interpreted using the...     

DTA and x-ray studies on extended-chain crystals of polyethylene under high pressure

The relation between the thermal behavior of extended-chain crystals (ECCs) of polyethylene and the phase transitions, i.e., orthorhombic ? hexagonal ? melt, of polyethylene at high pressures above about 400 MPa has been studied by high-pressure differential thermal analysis (DTA), and with a high-pressure and high-temperature x-ray diffraction apparatus equipped with a position-sensitive proportional counter measuring system. The original sample used in this study consists mainly of two kinds of ECC, which we designate as “ordinary extended-chain” crystals (OECCs) and “highly-extended-chain” crystals (HECCs). Experimental results at pressures below 300 MPa substantiate the results previously reported: i.e., the phase diagram indicating the relation between the melting temperatures and pressure for the OECCs and HECCs can be determined for pressures up to 500 MPa. In heating at pressures above about 500 MPa, the peak intensity of the (100) reflection of the hexagonal structure decreases in two stages with increasing temperature. The phenomenon corresponds to the thermal behavior determined by high-pressure DTA in which two small endothermic peaks can be observed at temperatures above that of the crystal transition evidenced by the strong peak. This phenomenon suggests melting in two stages of hexagonal structures with different thermal stabilities, and that the change at higher temperature may be due to fusion of the hexagonal phase annealed either below or above the transition temperature.     

Confined-growth crystallization of polyethylene

A new typical orientation pattern of polyethylene has been observed in extruded, melt-drawn composites containing 10% polyethylene and 90% polystyrene. In these composites, the polyethylene phase is dispersed in the polystyrene matrix as thin, long ribbons (width 1000 Å, thickness 500 Å). The b axis of the crystallites is found oriented preferentially along the long dimension of the ribbons, i.e., in the extrusion direction. The a and c axes of the crystallites show no preferred orientation. This texture pattern is attributed to the fact that, in view of the small cross section of the polyethylene phase, crystallization can proceed only along the long axis of the ribbons. Since the b axis is the direction of fastest growth in polyethylene (and the radial direction in a spherulite), most polyethylene unit cells are oriented with their b axes in the long dimension of the ribbons.     

Crystallization and melting of polyethylene under high pressure. II. Effect of pressure on melting behavior of various types of crystals

The effect of pressure on the melting point and volume of fusion of polyethylene was studied by high-pressure dilatometry. Starting materials were crystallized slowly from the melt under pressures of 1500, 3500, 5130 kg/cm², and 1 atm. It has been shown that the unusual behavior observed at pressures above 4000 kg/cm² is due to crystallization and melting of two kinds of extended-chain crystals differing in thermal stability. These are designated as ordinary extended-chain and highly extended-chain crystals, respectively. The relation between pressure P and melting temperature T_m of folded-chain, ordinary extended-chain, and highly extended-chain polyethylene was determined precisely. At pressures up to about 3000 kg/cm², plots of P against T_m for the crystal forms have almost the same curvature and then become parallel. But at pressures above 4000 kg/cm², ordinary extended-chain crystals show a linear increase of T_m with a constant slope of about 70 atm/deg. Curve for the highly extended-chain crystals changes in slope from 70 to 50 atm/deg at pressures between 3500 and 4300 kg/cm², and then show a sharp increase of T_m with increasing pressure. Experiments show that the meltingpoint curve of the highly extended-chain crystals overlaps that of the ordinary extended-chain crystals at pressures below 4000 kg/cm². Annealing experiments with folded-chain and ordinary extended-chain crystals have been made under high pressure. It is suggested that the formation of highly extended-chain crystals occurs stepwise through the formation and reorganization of ordinary extended-chain crystals from the original folded-chain crystals by a mechanism of partial melting and recrystallization at pressures above 4000 kg/cm².     

Lamellar thickening in polyethylene single crystals annealed under low and high pressure

Single crystals of linear polyethylene, prepared from a dilute xylene solution, were annealed below their melting temperature under atmospheric and 6 kbar pressure. In order to preserve the identity of the single crystals, they were suspended in an inert solvent medium, silicone oil and ethanol, during annealing. Examination of the annealed crystals under an electron microscope revealed development of numerous reorganization centers consisting of a central, elongated hole surrounded by a raised edge. Characteristics of these holes, especially their location and orientation, were interpreted in terms of the molecular packing that existed prior to the annealing and the mechanism of molecular reorganization that occurred during the annealing. The effect of high pressure was primarily to flatten out the crystals and to increase the number of reorganization centers, but the height of the raised edges remained about the same irrespective of the applied pressure. The present study also showed examples pointing to the importance of differentiating the annealing behavior of monolayer crystals from that of multilayer crystals.     

Overall crystallization kinetics of thin polymer films. General theoretical approach. I. Volume nucleation

A general theoretical approach of the overall crystallization kinetics of thin polymer films is developed. This new model makes it possible to calculate the evolution of the transformed volume fraction anywhere in the film, whatever the cooling conditions are. In its isothermal limit this model is equivalent to previous approaches which have been well verified by a computer simulation. In conclusion, it is pointed out that both isothermal and anisothermal determinations of crystallization kinetic parameters are greatly dependent on the sample thickness.     

A fourier transform infrared spectroscopic investigation of polyethylene single crystals. I. Methylene wagging mode

The application of the spectral subtraction routine to the determination of the morphology of polyethylene single crystals is discussed in detail. An analysis of the CH₂ methylene wagging mode is presented. A band at 1346 cm^?1 is observed to be unique to polyethylene single crystals. The assignment of this band to a regular, tight fold structure is discussed.     

Mixed-crystal infrared studies of chain folding in polyethylene single crystals: Effect of crystallization temperature

Mixed crystals of polyethylene (PEH) and various-molecular-weight perdeuterated polyethylenes (PEDs) have been prepared at 80°C and their infrared spectra compared with those of samples grown at 55°C. Concentrations of 80 PEH/1 PED were required in the former case to eliminate segregation effects whereas 40 PEH/1 PED sufficed in the latter. Resolution of the observed CD₂ bend contour was most reasonably achieved with a crystalline singlet and two crystalline doublets, in addition to a contribution (ca. 15%) from the noncrystalline component. The singlet, comprising about 20% of the crystalline area, contains contributions from both isolated stems and (200) adjacent reentry folding. Random reentry folding is therefore not a predominant mode of chain organization in polyethylene single crystals. The inner of the two doublets arises from adjacent reentry folding along single (110) planes, and is present for all PED molecular weights. For low-molecular-weight fractions this splitting is consistent with the number of stems of one PED molecule allowed in the crystal. The outer doublet arises from multiple (110) plane adjacency, and is present for intermediate and high molecular weights. An analysis of both doublets suggests that at high molecular weights a single molecule can crystallize with noncontiguous regions of adjacent stem domains.     

Fold surface of polyethylene single crystals as assessed by selective degradation. I. Ozone degradation method

Ozone has been used as a selective oxidizing agent for degrading polyethylene single crystals at room temperature in order to confirm and extend results on surface structure obtained by use of fuming nitric acid at temperatures above 60°C. The surfaces of the crystals were rendered highly accessible to the ozone gas by preparing the crystalline material in a highly expanded form; the solvent in which the crystals were suspended was removed by sublimation from the solid state. The extent and nature of the reaction were studied by measuring the increase in weight and in density, by direct chemical analyses, and by making use of infrared spectroscopy and gel-permeation chromatography. It was found that the surfaces of the crystals are attacked at room temperature by ozone, with resulting chain scission, and the broad features of the chemical reaction were established. Some folded chains are found to be as long as the original thickness of the crystal, and once folds have been cut, continuing reaction shortens the chains. In the early stages of the degradation, during which most of the weight increase takes place, the density of the crystals increases, and the magnitude of the increase is that expected from the increase in weight alone, i.e., assuming no increase in effective volume.