Extended-chain crystals. I. General crystallization conditions and review of pressure crystallization of polyethylene

This is the first paper of a series of reports concerning extended-chain crystals of flexible, linear high polymers. The general conditions for crystal growth are discussed. Polymer crystallization is described as a two-step process: nucleation of each crystallizing molecule to a folded-chain conformation, followed by an increase in fold length in a solid-state reorganization step. This reorganization step is enhanced in the case of polyethylene by crystallization at high temperature under elevated pressure. Mechanical deformation during crystallization is also able to produce extended-chain crystals. The most promising method, however, is crystallization during polymerization. Previous work on crystallization of polyethylene under elevated pressure is critically reviewed.     

Crystallization of short aliphatic polymer chains. I. General chain-folding behavior

Short aliphatic polymer chains of different lengths were prepared by degrading polyethylene samples of appropriately chosen initial fold lengths to the chain lengths which correspond to a single chain traverse through the lamella. The resulting dicarboxylic acids were either used as such for further crystallization experiments or were first converted into diiodides to remove polar endgroups. The resulting short polymers all crystallized by chain folding even if the chains (peak of distribution) were only 1.5–4 times the length of a traverse through the lamella. In the diiodides the fold length varied continuously with crystallization temperature, as is usual in high molecular weight material, but with the dicarboxylic acids such variation, while observable, was only small. The effect of the molecular weight on the fold length due to its influence on supercooling at a given crystallization temperature has become apparent. Renewed degradation with nitric acid and subsequent GPC analysis of the degradation products confirmed the folded nature of the chains in the above crystals. This analysis combined with experiments on the reactivity of chain ends has led to the picture that each chain folds completely, once, twice etc. so that both folds and ends are in the surface zone but are located at varying heights, as appropriate to the overall layer thickness for the molecular weight distribution in question. This picture is consistent with other concurrent work.     

Crystal nucleation of polymers confined to droplets: Memory effects

We study crystal nucleation within an ensemble of polyethylene droplets created through the dewetting of a thin film on an unfavorable substrate. In particular, we employ standard thermal treatment procedures to induce self-nucleation in samples to gain some insight into the nature of this enhanced crystallization. The novel sample-geometry enables the monitoring of each droplet throughout successive experiments, and hence the changes in their nucleation mechanism for various thermal treatments. We find a consistent self-nucleated crystallization temperature of ∼101 °C under all conditions, suggesting uniformity in the centers which facilitate nucleation. Using correlation plots, we demonstrate that the observed melt-memory effects have a stochastic rather than deterministic nature; self-nucleation is a random process. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 3438–3443, 2005     

Crystallization of polyethylene at elevated pressures

The crystallization from the melt of three sharp polyethylene fractions has been studied at 5 kbar. It has been shown that the thickness of so-called extended-chain lamellae is a function of time, temperature, and molecular weight. There is by no means just the fully extended molecular configuration present. Crystallization is qualitatively similar to that of chain-folded crystals at 1 bar, giving an optimum lamellar thickness which increases with time and decreasing supercooling. Fractional crystallization is widespread and is a major cause of disparate lamellar thickness. Isothermal thickening of lamellae during crystallization has been established directly. Morphological detail suggests further that layers can increase their thickness tenfold over their initial size.     

Effect of crystallization time on the properties of melt-crystallized linear polyethylene

Linear polyethylene was crystallized isothermally from the melt. Specimens were removed at different crystallization times and quenched to room temperature. The density, static mechanical properties, and small-angle x-ray scattering (SAXS) behavior of these specimens were measured at room temperature. The density and Young's modulus increased with crystallization time, whereas the upper yield point decreased with crystallization time. SAXS data showed that a zero-angle peak gradually disappeared as crystallization time increased. Concurrently, the breadth of the SAXS peaks, the Bragg angle, and the integrated intensity decreased. Changes in the ratio of second- and first-order peak intensities were also noted. On the basis of the SAXS and density data, it was concluded that a competition exists between the thickening of existing crystals and the creation of new crystallites between the older ones. At relatively low crystallization times, numerous new crystals can form during quenching to room temperature, whereas quenching after prolonged crystallization primarily results in the additional thickening of existing crystals. No change in the density of the amorphous material is found. A model is given whereby the upper yield stress is coupled to these morphological changes through a stress concentration effect caused by a decreased population of chains connecting adjacent crystallites. The tie-chain population change occurs by their elimination as crystallites disappear.     

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.     

Studies on polyethylene crystallized at unusually high supercoolings: Fold length,habit, growth rate,epitaxy

The newly arisen possibility of crystallizing polyethylene at supercoolings much higher than were achievable previously has enabled the study of crystallization to be extended in several directions. Thus, fold length can be followed down to previously inaccessibly low crystallization temperatures, in the present case with sharp fractions, demonstrating the essential independence of the fold length of molecular weight. In this context the thinnest isolated crystal reported so far was obtained (ca. 6 nm). The faceted nature of crystals grown at such low temperatures and high rates has been noted, and is in line with new conceptions of polymer crystal growth. A previous observation of exceptionally high crystal growth rate (ca. 2 m/s) has been supplemented by measurements over a range of crystallization temperatures and the results found to be in good agreement with the predicated regime III behavior in the least theory of Hoffman. Observations of epitaxy on mica, while broadly in line with those by Lovinger, were revealing in several respects. Among these the observation that the substrate can influence the fold length when the chains are parallel to the substrate plane remains unexplained and puzzling.     

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

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

Fold length of single crystals of polystyrene: A conflict with crystallization theories at high supercoolings

The purpose of the work was to test existing theories of chain folded polymer crystallization over a supercooling range which is much is excess to what could be hitherto realized. This was made possible by the recognition that crystallization of isotactic polystyrene in solution could be conducted over an exceptionally wide range of temperatures in an isothermally controlled manner. The results revealed that the familiar inverse dependence of the fold length on supercooling (the behavior observed and studied in polyethylene) was only displayed at the lowest supercooling; at high supercoolings the fold length reached a constant lowest value unaffected by further lowering of the crystallization temperature. This is in conflict with present theories, which predict a catastrophic upswing in fold length at high supercoolings. It is demonstrated that the observations cannot be made compatible with this prediction by any conceivable adjustment of the numerical parameters. The implications of these findings are discussed.     

Polymer decoration: The orientation of polymer folds as revealed by the crystallization of polymer vapors

A new technique of decoration of the fold surface of polymer crystals is described. It is similar in methodology to gold decoration, but makes use of vapors of crystallizable polymers, principally polyethylene, as decorating material. Upon condensation and crystallization, the highly anisometric decorating molecules become oriented parallel to the fold direction. They build up small crystalline lamellae which, seen edge-on, appear as elongated rods and can be easily observed by conventional transmission electron microscopy. This decoration technique reveals the sectorization of polymer single crystals grown from solution. It can be used to determine the local fold orientation (with a resolution of ca. 10 nm) of polymers crystallized under a wide range of conditions, including crystallization from the bulk. The technique reveals that under all crystallization conditions so far investigated the outermost part of the polymer fold surface is relatively ordered, and the folds and/or loops are, as a rule, oriented nearly parallel to the macroscopic growth front.     

The initial stages of crystallization of polyethylene from the melt

Synchrotron x-radiation has been used to follow the development of low-angle diffraction in sharp fractions of polyethylene. The polymer is shown to crystallize in very thin lamellae which rapidly thicken in a single step to twice, three times, or four times the original thickness. This dramatic refolding is more pronounced at higher crystallization temperatures. After the sudden integral jumps in fold length, the thick lamellae continue to grow thicker logarithmically with time. The significance of these findings for the most basic issues of polymer crystallization and for the experimental methodology of its study is highlighted.     

Fold surface of polyethylene single crystals as assessed by selective degradation studies. III. Application of the improved techniques to single crystals

Previous studies on selective degradation of polyethylene single crystals with fuming nitric acid have been extended, both by using acid of lower concentration which gave better control over the degradation, and by resorting to ozone as an oxidizing agent which among others enabled the degradation temperature to be conveniently lowered. The molecular weight distribution was followed by gel-permeation chromatography in the course of degradation. Complete consistency between these different methods has been established, modifying some of the previous conclusions reached by this method. The principal feature which emerges is that we have a distribution of fold lengths. The largest straight fold stems can stretch across nearly the entire layer defined by the low-angle x-ray period, while there is a continuous distribution of shorter folds terminating deeper down in the crystals. The limiting depth at which the number of terminating folds becomes negligible can be identified and quantitatively assessed. The method of analysis is described, and individual data are discussed in detail. This picture of a fold surface layer containing essentially adjacently reentrant folds of uneven length agrees with quite recent results on other related chain-folded systems (annealed crystals, short chains, bulk structures) obtained in these laboratories and thus appears to be of general validity. The consequences of the model for our picture on polymer crystals in particular on the nature of the “amorphous” component, are discussed.     

Survey of the long spacing of polyamides crystallized from solution

A series of linear, aliphatic polyamides in which the number of carbon atoms in the repeat unit ranged from three to twenty-four was crystallized from solution. All gave lath-shaped crystallization products (usually aggregated in the form of sheaves) that were unmistakable lamellar. Sedimented mats of the crystals were examined by lowangle and wide-angle x-ray diffraction. Each polyamide had a characteristic layer thickness (fold length) which was determined by the length of the repeat unit and the number of hydrogen bonds in the lamella. The thickness was independent of other variables examined including crystallization conditions. The polyamides studied cover a wide range: they border on polypeptides at the one extreme and approach polyethylene at the other. For all these materials there emerged a unifying pattern which relates chemical structure directly to chain folding.     

Solution grown isotactic polystyrene crystals. I. Degree and distribution of crystallinity; thermal stability

The subject of this paper is the degree of crystallinity and annealing behavior of solution grown single crystals of isotactic polystyrene (IPS) in relation to the fold length, an enquiry which acquires special significance in view of the fact that previously the fold length had been found to be identical over a wide range of crystallization temperatures (T_c). It was found that both crystallinity and thermal stability increase with T_c even over the range of constant fold length thus invalidating the usual assumption that the fold length and crystal properties are uniquely correlated. Further, the crystallinity figures as measured by conventional calorimetry are very low (<50% throughout) which by conventional ideas would require an unrealistically thick amorphous surface layer. However, the “linear crystallinity” (crystal core thickness as determined from x-ray linewidths) is much larger, commensurate with crystallinities in single crystals from other materials. It is suggested that this is the more relevant figure for the subdivision of the lamellas into crystal core and surface layer. The additional amorphous content being otherwise accommodated. Further, this “linear crystallinity” is broadly unaffected by fold length changes induced by heat annealing. The thermal stability (including annealing ability) of the crystals differs markedly whether T_c is above or below ～60°C, a T_c value which is in the range where the fold length is constant, but corresponds to a maximum in the crystallization rate. Possible connections between crystallization conditions and the stability of the resulting crystals (fold length considerations apart) are pointed out.     

Crystallization kinetics of linear polyethylene: The maximum in crystal growth rate-temperature dependence

This rapid communication reports a summary of the key findings of crystallization kinetics studies of unfractionated high density (linear) polyethylene at extremely large supercoolings. We report, for the first time, the maximum in crystal growth rate-crystallization temperature data for linear polyethylene, which has been sought by many researchers since the 1950s. The maximum growth rate was found to occur in the range of 70-75 °C with two separate methods. The kinetics studies were performed using a newly developed quench-crystallization technique based on depolarized reflection light microscopy that is capable of achieving enormously higher quench rates than existing methods. Typical onset crystallization temperatures accessed with this technique range from 40 to 90 °C. Bulk growth rates of crystals were obtained as the reciprocal of crystallization half times measured from the change in the depolarized light intensity upon direct crystallization from the melt. Separately, radial growth rates of spherulites were measured over a wide range of supercoolings. Secondary nucleation analysis of the crystal growth rates resulted in single linear fits extending into deep regime III, suggesting no change in mechanism of formation of the crystals at the largest supercoolings. The deeply quenched films, crystallized at temperatures below the maximum, contain non-impinged spherulites, capable of further crystallization.     

SOLUTION CRYSTALLIZATION OF METALLOCENE SHORT CHAIN BRANCHED POLYETHYLENE:MORPHOLOGY AND MECHANISM*

Solution crystallization of metallocene short chain branched polyethylene (SCBPE) was carried out and very nicesingle crystals were obtained. Compared with single crystals grown from linear polyethylene, SCBPE single crystals are dirtydue to intermolecular heterogeneity The crystal morphology changes with crystallization temperatures. Lozenge, truncatedlozenge, hexagonal, rounded and elongated crystal morphologies have been found at much lower crystallization temperaturethan in linear polyethylene. The electron diffraction shows there is a possibility that the single crystals may have hexagonalpacking in a crystallization temperature range. The lateral habits of single crystal are discussed based on roughening theories.     

Crystallinity and the effect of ionizing radiation in polyethylene. I. Crosslinking and the crystal core

An extensive study has been carried out on the effect of ionizing radiation on polyethylene in the form of solution-grown single crystals to follow up preceding investigations which had indicated that the radiation-induced effects along the fold surfaces could be significantly different from those within the crystal interior. In this first part of the series, radiation-induced crosslinking was investigated in the case of “crystal core” material. This material, obtained by removal of the fold surface by oxidative degradation with ozone, consists of isolated foldfree crystal layers of dicarboxylic acids of uniform length, the length itself depending on the fold length of the starting crystal. This “core material” was irradiated by γ rays and the effect of crosslinking was followed by GPC analysis by recording the development of dimer, trimer, etc., peaks in the chromatograms. For a given dose, the fractional amount of crosslinked material is independent of the chain length. This, together with other effects described, provides unambiguous evidence that crosslinking occurs at the chain ends or, in other words, that there is no crosslinking within the interior of the paraffinoid lattice. Further, no permanent scission was observed to occur within the lattice, at least in amounts detectable by the present molecular weight measurements. The obvious significance of these effects for radiation studies on paraffinoid substances in general, beyond those of the present long-chain dicarboxylic acids, is discussed prior to utilizing them in the study of chain-folded polyethylene crystals in the following parts of the series.     

Specific reversible melting of polyethylene

The specific reversibility of the crystallization and melting of linear and branched polyethylene has been determined as function of temperature by temperature‐modulated differential scanning calorimetry. The specific reversibility of crystallization and melting is defined as the ratio of the reversible enthalpy to the total enthalpy of the transition, both measured at the same temperature. This definition emphasizes a close connection between the reversible and irreversible parts of the transition. As one would expect, the crystal‐to‐melt transition of a given portion of a sample can only be reversible at a temperature close to its own temperature of irreversible melting. Reversible melting is absent at temperatures far from irreversible melting, and this is usually seen by experimentation as its zero‐entropy production melting temperature. The reversible change in the fold length, in contrast, is observed far from the melting temperature of the crystal involved. The specific reversibility of the crystallization and melting of polyethylene crystals may exceed 50% outside the temperature range of the main crystallization and melting. The specific reversibility seems rather independent of the branch concentration, and this points to similar mechanisms of the reversible transition in linear polyethylene of high crystallinity and in branched polyethylene of low crystallinity. The reversible transition is due to a local equilibrium at the crystal surface and is, therefore, largely independent of the overall morphology of the sample. In this study, a model is developed that is based on partial molecular melting, which avoids the need of molecular nucleation and permits, therefore, reversible melting as seen for small molecules in the presence of crystal nuclei. It provides an explanation of the rather large number of the crystals that may participate in reversible melting and allows a connection to the fully reversible crystallization of paraffins and the fully irreversible crystallization of extended‐chain crystals of high crystallinity. © 2003 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 41: 2157–2173, 2003     

Nonintegral and integral folding crystal growth in low-molecular mass poly(ethylene oxide) fractions. I. Isothermal lamellar thickening and thinning

The overall crystallization and crystal melting of one low-molecular mass poly(ethylene oxide) (PEO) fraction (MW 3000) have been investigated by differential scanning calorimetry (DSC) and in situ small-angle x-ray scattering (SAXS). The salient new results indicate that initial transient crystals with nonintegral folding (NIF) chain lengths form over a wide range of crystallization temperatures. This NIF structure subsequently transforms into crystal forms with integral folding (IF). The PEO IF crystals consist of the extended chain (n = 0) crystal and the once-folded chain (n = 1) crystal, while the NIF has an intermediate fold length. The NIF → IF transformation occurs either by lamellar thickening or thinning. The NIF crystal is less stable than the IF(n = 1) crystal, but its growth is more rapid. Crystallization of the PEO (MW 3000) fraction is thus recognized as a compromise between the direction of the thermodynamic driving force and the kinetic pathway. Some potential consequences of these observations are also addressed.     

Chain-folding measurements in annealed poly(ethylene terephthalate)

Chain folding in unoriented poly(ethylene terephthalate) (PET) films has been investigated as a function of annealing time and temperature. To meet this objective dynamic mechanical, infrared, and molecular weight measurements were used, together with selective chemical degradation to remove chain folds and amorphous regions. The β dispersion in the dynamic mechanical spectrum of PET is here tentatively associated with motions of methylene and/or carboxyl groups in irregular chain folds; the β dispersion is not found in quenched amorphous polymer, in polymer where amorphous regions and chain folds have been removed, or in highly annealed PET where the irregular folds have regularized. Upon mild crystallization and annealing (30 min at 110°C) of initially amorphous film a large β dispersion appears and then diminishes upon further annealing at 220°C. As the β dispersion diminishes, the infrared regular fold band increases more than the crystallinity band, indicating regularization of folds. The molecular weight of the degraded residue corresponds approximately to typical fold-period dimensions (～130 Å), and increases on annealing as expected from lamellar thickening. The degradation process has, by fold removal, reduced the chains in the crystals to a very short, uniform length.