Influence of initial polymer concentration in solution and weight-average molecular weight on the drawing behavior of polyethylenes

The influence of initial polymer concentration in solution (c), weight-average molecular weight (M_ω), and drawing temperature on the solid-state drawing behavior of linear polyethylenes was investigated. Optimum conditions, with respect to maximum attainable draw ratio, are observed in isothermal drawing experiments. Moreover, it is shown that high maximum attainable draw ratios can also be obtained upon multistage drawing of UHMW-PE (ultrahigh-molecular-weight polyethylene, M_ω > 10⁶ g/mol) gel films cast from concentrated solutions. The high maximum attainable draw ratio in combination with the high molecular weight (M_ω > 10⁶ g/mol) and polymer concentration (c = 10% w/v) is of particular interest because it results in tapes or fibers with a high Young's modulus (100 GPa) and tensile strength (2.5–3.5 GPa). It is also shown that the maximum attainable draw ratio of polyethylenes scales with the Bueche parameter (c · M_ω) to the ?0.5 power. This experimental observation indicates that intermolecular interactions not only dominate the rheological properties of polyethylene melts and concentrated solutions, but also strongly influence the solid-state drawing behavior of linear polyethylenes.     

Effects of molecular characteristics and processing conditions on melt‐drawing behavior of ultrahigh molecular weight polyethylene

The effects of molecular characteristics and processing conditions on melt‐drawing behavior of ultrahigh molecular weight polyethylene (UHMW‐PE) are discussed, based on a combination of in situ X‐ray measurement and stress–strain behavior. The sample films of metallocene‐ and Ziegler‐catalyzed UHMW‐PEs with a similar viscosity average MW of ～10⁷ were prepared by compression molding at 180 °C. Stress profiles recorded at 160 °C above the melting temperature of 135 °C exhibited a plateau stress region for both films. The relative change in the intensities of the amorphous scattering recorded on the equator and on the meridian indicated the orientation of amorphous chains along the draw axis with increasing strain. However, there was a substantial difference in the subsequent crystallization into the hexagonal phase, reflecting the molecular characteristics, that is, MW distribution of each sample film. Rapid crystallization into the hexagonal phase occurred at the beginning point of the plateau stress region in melt‐drawing for metallocene‐catalyzed UHMW‐PE film. In contrast, gradual crystallization into the hexagonal phase occurred at the middle point of the plateau stress region for the Ziegler‐catalyzed film, suggesting an ease of chain slippage during drawing. These results demonstrate that the difference in the MW distribution due to the polymerization catalyst system dominates the phase development mechanism during melt‐drawing. The effect of the processing conditions, that is, the including strain rate and drawing temperature, on the melt‐drawing behavior is also discussed. The obtained results indicate that the traditional temperature–strain rate relationship is effective for transient crystallization in to the hexagonal phase during melt‐drawing, as well as for typically oriented crystallization during ultradrawing in the solid state. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 2455–2467, 2006     

Pecularities of the thermomechanical behaviour of ultra-high molecular weight linear polyethylene and its blends with linear polyethylene of normal molecular weight

Ultra-high molecular weight polyethylene UHMWPE (M _w=4 · 10⁶,I _s=O g/ 10 min), high density polyethylene of normal molecular weight NMWPE (I _s= 4.8 g/10 min) and their blends have been investigated by means of thermomechanical loading in constant and impulse regime. It has been established that after melting, NMWPE passes to a viscous-liquid state. After melting at 138 °C UHMWPE passes to a high-elastic state. The transition of UHMWPE to a viscous-liquid state takes place at temperatures higher than 180 °C and is accompanied by a high-elastic reversible deformation. The blends of UHMWPE with 10 and 20 mass % of NMWPE show a plateau on the thermomechanical curves, corresponding to a high-elastic state, in a shorter temperature range where the deformation is greater. The blends containing the higher percent of NMWPE show thermomechanical curves lacking such a plateau. All blends are characterized by a singular thermomechanically defined temperature of melting, which increases with increase of UHMWPE content. The existence of the high-elastic state in the curves of UHMWPE and its blends containing NMWPE less than 30 mass % above their melting temperatures is explained by the high degree of physical crosslinking of UHMWPE.     

Coextrusion drawing of reactor powder of ultrahigh molecular weight polyethylene

Certain nascent polymers have been shown to have unusual thermal and morphological properties that are irretrievably lost once the polymer has been melted or otherwise reduced to the isotropic state. We show further that nascent ultrahigh molecular weight polyethylene “reactor powder” exhibits a remarkable ductility when uniaxially drawn by coextrusion techniques after initial compaction in film form at 100°C. When drawn at a temperature of 110°C, draw ratios of 56 have been obtained, resulting in an enhanced tensile modulus of 58 GPa. Thermal analyses and dynamic mechanical measurements were also made towards understanding the initial and final morphologies.     

The drawing behavior of polyethylene copolymers

The tensile drawing behavior of a range of selected polyethylene copolymers has been studied. Sheets were prepared by quenching molten polymer into cold water. Two-centimeter-gauge-length samples were then drawn in air at 75 or 115°C in an Instron tensile testing machine at a crosshead speed of 10 cm/min. It was found that even at the very low concentration of one side branch per 1000 carbon atoms there was a very marked effect on the strain hardening behavior and the maximum draw ratio that could be achieved. The reduction in draw ratio increased with increasing branch concentration, and long branches were more effective than short branches in limiting the draw ratios achieved. The similarity between these effects and the effects of increasing M?_w or radiation crosslinking is noteworthy. This suggests that even a very small concentration of branches can significantly reduces the moleculer motions required for the process of plastic deformation. The Young's modulus/draw ratio relationship follows a pattern virtually identical to that observed in the case of homopolymers.     

Drawing behavior of linear polyethylene. II. Effect of draw temperature and molecular weight on draw ratio and modulus

The drawing behavior of linear polyethylene homopolymers with weight-average molecular weights (M?_w) from 101,450 to ca. 3,500,000 has been studied over the temperature range 75°C to the melting point. In all cases 1-cm gauge length samples were drawn in an Instron tensile testing machine at a constant cross-head speed of 10 cm/min. With the exception of the lowest molecular weight polymer, it was found that increasing the draw temperature led to substantial increases in the maximum draw ratio which could be achieved, and that this increased monotonically with increasing draw temperature. Measurements of the Young's modulus of the drawn materials showed, however, that the unique relationship between modulus and draw ratio previously established for drawing at 75°C was not maintained to the highest draw temperatures. The highest draw temperature at which this relation held was found to be strongly molecular weight dependent, increasing from ca. 80 to ca. 125°C when M?_w increased from 101,450 to 800,000. In all cases conditions could be found for drawing samples to draw ratios of 20 or more with correspondingly large values of the Young's modulus.     

Determination of initial and long-term microstructure changes in ultrahigh molecular weight polyethylene induced by drawing neat and pyrenyl modified films

Deformation processes in gel-crystallized ultrahigh molecular weight polyethylene (UHMWPE) films with draw ratios (DR) as high as 96 have been investigated by X-ray diffraction (XRD), differential scanning calorimetry (DSC), and positron annihilation lifetime spectroscopy (PALS). In addition, low concentrations of pyrene molecules have been introduced at the time of film preparation from the gels or afterward by sorption after film preparation, and the polarization of their electronic absorption and fluorescence spectra at different draw ratios has been measured over a large temperature range extending to below the glass transition. The pyrene-doped films have been irradiated to introduce covalently attached 1-pyrenyl groups, and these films at two draw ratios have been employed to investigate over large temperature ranges (1) the steady-state fluorescence intensity and (2) the rates of diffusion of N,N-dimethylaniline (DMA). These data have been correlated with the XRD, DSC, and PALS information obtained on the unmodified films. On the basis of analyses of this body of information, a novel deformation model that explains the decreased crystallinity and increased mean free volumes in gel-crystallized UHMWPE at low draw ratios is proposed. It involves "stretch" and "flip" motions of microfibrils present in the undrawn films. The high crystallinity content and stiffer chains due to drawing UHMWPE films result in weak alpha- and beta-relaxation processes, slower diffusion of DMA than in undrawn films, and orientation factors for doped pyrene molecules that are constant over a large temperature range. The overall picture that emerges allows several aspects of the morphology of UHMWPE, a polymer of fundamental importance in materials research, to be understood.     

Morphology and melting behavior of nascent ultra-high molecular weight polyethylene

The nascent morphology of UHMW PE exhibits high melting point, high crystallinity, and increased WAXS line breadth relative to samples formed by melt crystallization. Different empirical relationships between crystal size and melting point are observed for nascent and molded samples. This differentiation is removed following nitric acid treatment of the nascent flake. Solid-state annealing behavior is differentiated by several regimes. Regime I is characterized by increasing crystallite dimensions and crystallinity at low annealing temperatures. Regime II[a] and II[b] is identified by double melting in DSC scans of moldings and nascent flake, respectively. The double melting is due to partial melting with incomplete recrystallization. Regime II[a] of moldings is differentiated from Regime II[b] of flake by an increase in melting point of the higher melting endotherm. Within Regime II[b], the partial melting of the nascent structure is sensitive to the distribution of morphological stability. Regime III is initiated at annealing temperatures approaching the zero heating rate melting point, and shows melting kinetics by DSC or time-resolved WAXS using synchrotron x-ray radiation. The superheat, partially associated with Regime III behavior, is sensitive to morphological heterogeneity and annealing history. Morphological models are discussed which highlight the role of noncrystalline regions and melting kinetics on the melting behavior of nascent form crystallinity. © 1998 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 36: 495–517, 1998     

Electron microscope study of low molecular weight fractions of linear polyethylene

Electron microscope studies are reported for crystals of linear polyethylene formed in dilute solution from very sharp low molecular weight fractions. Emphasis is placed on molecular weights in the range of 1.1 × 10³ to 15.1 × 10³. The dependence of the crystal habit on the crystallization temperature is very similar to that which has been found for the higher molecular weight species. However, the demarcation temperature for the crystallization of the different morphological forms is very molecular weight-dependent. The conditions under which interfacial dislocation networks form can be clearly defined. The molecular weight must be less than 3000, so that these structures are restricted to very small chain lengths. However, not all crystallization conditions within this allowable molecular weight range yield such dislocations. The formation of interfacial dislocation networks are shown to occur only under very special circumstances. Their occurrence clearly cannot be offered as evidence, as has been done in the past, for a regular, chain-folded interfacial structure.     

Fluctuation-dissipation relations for polymer systems. I. The molecular weight dependence of the viscosity

Generalised Langevin equations are used to describe the motion of interacting polymer molecules. In these equations the many-body aspects of the problem are incorporated into generalised friction functions and random forces. The so-called second fluctuation-dissipation relation gives a general relation between these two quantities and enables us to relate the spatial correlations present in the environment to a normal mode dependent friction coefficient and force constant. We then show how the various regimes of molecular weight dependence of the viscosity can be understood in a fairly general and non-specific way in terms of the spatial correlations of the random forces representing the rest of the system of polymer and solvent molecules. In particular a molecular weight dependence of M³ is shown to be a general feature of a spatially corelated environment.     

Polymerization beyond the gel point. I. The molecular weight of sol as a function of the extent of reaction

Theoretical expressions for describing the weight-average molecular weights of the soluble fractions from polymerizations obtained beyond the gel point were tested experimentally. The theory of branching processes and a recursive approach essentially based on the method of Macosko and Miller were found to be virtually equivalent. The soluble fractions produced from the stoichiometric polymerization of 1,3,5-benzenetriacetic acid (BTA) with decamethylene glycol (DMG) gave molecular weights and distributions in excellent qualitative agreement with the theory. The results are interpreted in terms of intramolecular cyclization, diffusion, and the presence of microgel particles.     

Effect of molecular structure on polyethylene melt rheology. I. Low-shear behavior

The melt rheological properties of both linear and branched polyethylene were investigated by use of narrow molecular weight distribution fractions and experimentally polymerized samples. Studies carried out in steady shear and in oscillatory shear yielded information concerning both the melt viscosity and the melt elasticity as a function of molecular structure, where the latter was characterized by various solution property techniques. The 3.4–3.5 power dependence of the low shear limiting viscosity on molecular weight was confirmed for linear polyethylene. The effect of long-chain branching on rheological properties was defined both at constant molecular weight and at constant molecular weight distribution and coupled with variation of molecular weight.     

Hydrostatic extrusion of linear polyethylene: Effects of molecular weight and product diameter

Oriented rods of linear polyethylene have been prepared by hydrostatic extrusion at 100°C. Materials having a range of different molecular weights were investigated and their behavior was found to correlate well with the melt flow index. The differences in extrusion process characteristics for large- and small-diameter products are discussed. In this context the effect of deformational heating is important and criteria are suggested for determining its significance and also for determining the stability of the process in terms of a critical extrusion pressure.     

Moderately concentrated solutions of polystyrene. I. Viscosity as a function of concentration,temperature, and molecular weight

Data on the viscosity η of moderately concentrated solutions of polystyrene are reported. Several solvents were investigated, including cyclopentane solutions over a temperature span between θ_U = 19.5°C and θ_L = 154.5°C. The data were analyzed in terms of a relation giving η as a function of αφM, where α_φ is the expansion factor for the chain dimensions in a solution with volume fraction φ of polymer with molecular weight M. It is shown that values of α_φ so determined decrease as ? lnα_φ/? lnφ = (1 ? 2μ)/6μ for φ greater than φ^* = 0.2M/s³ for moderately concentrated solutions, where s is the root-mean-square radius of gyration and μ = ? ln[η]/? lnM with [η] the intrinsic viscosity.     

Polymerization mechanisms and molecular weight distribution. I. Mathematical treatment

A novel method for determining the polymerization mechanism and the kinetic rate constants from the molecular weight distribution is proposed. The particular criterion function used as basis for parameter adjustment is where θ is the vector of dependent variables, y(r, θ) is the theoretical molecular weight distribution for the assumed polymerization mechanism, and y_E(r) is the experimental molecular weight distribution which is a function of the chain length r. A form of the gradient method of optimization was used to solve the criterion function. The proposed method is particularly powerful since the whole molecular weight distribution is utilized.     

Solid-State coextrusion of high-density polyethylene. II. Effect of molecular weight and molecular weight distribution

The recently developed technique of solid-state coextrusion for ultradrawing semicrystalline thermoplastics has been applied in the preparation of self-reinforced high-density polyethylene extrudates. The extrudates consist of definite core and sheath phases composed of different molecular weights (M_w) in the range of 60,000–250,000 and different molecular weight distributions (M_w/M_n = 3.0–20). Concentric billets of two different phases were prepared for extrusion by in serting a polyethylene rod within a tubular billet of a different high-density polyethylene followed by melting the two phases to obtain bonding between them. The billet was then split longitudinally to increase extrusion speed and extruded at 120°C, 0.23 GPa through a conical die of extrusion draw ratio 25. Extrudates of high tensile modulus (38 GPa) and strength (0.50 GPa) could be produced in a steady state process at a rate near 0.25 cm/min. The tensile properties of the extrudates from either the single or concentric billets increased with average molecular weight and were insensitive to the molecular weight distribution of the constituent phases. Thermal analysis indicated a high deformation efficiency for the sheath and core phases of the extrudates by the coextrusion technique.     

Sensitive phase separation behavior of ultra-high molecular weight polyethylene in polybutene

Thermally induced phase separation (TIPS) has prompted a great deal of interest, especially as an effective approach to fabricate ultra-high molecular weight polyethylene (UHMWPE) microporous membranes. However, the existing utilized diluents for the TIPS process of UHMWPE suffer from environmental and health issues. Herein, we utilized low molecular weight polybutene (PB) bearing similar structure with liquid paraffin (LP) but inferior miscibility with UHMWPE relative to UHMWPE/LP blend, as a diluent for the TIPS process of UHMWPE. The phase separation behavior of UHMWPE/PB blends were investigated by the combination of rheological measurements, optical microscopy as well as differential scanning calorimeter (DSC). The results suggest that PB is fully miscible with UHMWPE at elevated temperature, but yielding a more sensitive phase separation behavior in respect to LP in TIPS process, because PB has weaker interaction with UHMWPE. The Jeziorny method analysis indicates that the crystallization mechanism of UHMWPE/LP blends is in line with that of UHMWPE/PB blends, which includes nucleation and growth as well as their dynamic competition. Moreover, compared to those of UHMWPE/LP blends, UHMWPE/PB blends display higher TIPS temperature and faster TIPS rate along with faster overall crystallization rate, further demonstrating that PB can accelerate phase separation rates and enhance the efficiency of TIPS process.