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.     

Self-hardening of highly oriented polyethylene

Ultra-oriented polyethylene fibers obtained by drawing to approximately 30 times their original length have a Young's modulus of approximately 800 kbar. Such fibers, if unconstrained, contract on heating to a length near the original. We have studied the forces causing this contractile behavior by monitoring the stress in the fiber while maintaining it at constant length. In the course of this we observed a complex sequence of both reversible and irreversible behavior. In the reversible case we observed first energy and then entropy elastic behavior. The most significant feature observed is that at sufficiently high temperature the fiber stress relaxes to an unmeasurably low value. A fiber allowed to relax in this way possesses a much lower room temperature tensile modulus (ca. 80 kbar) immediately after relaxation but, remarkably, this modulus increases to approach the initial high value over a period of a few hours when the fiber is stored either clamped or unclamped at room temperature. High x-ray orientation is preserved throughout the storage period but the density which dropped during the stress decay rose again in the course of the spontaneous stiffening. None of the stress relaxed fibers displays large-scale contractile behavior on subsequent heating. A phenomenological composite model is proposed which involves stiff microfibrils of short length—surrounded by a matrix present as a minority component. The softening of this matrix on heating and its subsequent stiffening on storage, involving a certain amount of melting and recrystallization, respectively, could then be responsible for the observed variations in the macroscopic tensile properties using simple fiber composite theories. The fibers are likely to be of extended-chain type produced by the initial drawing while the matrix may consist of a combination of oriented amorphous material (tie chains), randomly oriented chains, and transverse lamellar overgrowth present in varying proportions in the different stages of sample treatment. The wider implications, fundamental and practical, of this remarkable self-hardening process are indicated.     

Non-isothermal crystallization of polyethylene blends with bimodal molecular weight distribution

Non-isothermal crystallization of polyethylene (PE) blends with bimodal molecular weight distribution (MWD) was investigated by differential scanning calorimetry (DSC) at various scanning rates. The bimodal PE blends were prepared by blending two unimodal polyethylenes with large difference in molecular weigh in different ratio in xylene solution. Different kinetic parameters such as the half-time of crystallization (t_1/2), crystallization rate constant (Z_c), F(T) and the effective activation energy were determined. Some complicated relationships between these parameters and the average molecular weight were found. The crystallization rate first increased and reached a maximum then decreased, and also correlated with the MWD. The Avrami index under non-isothermal conditions was analyzed with a method developed by Harnisch and Muschik; the results indicated that homogeneous nucleation and spherulitic growth regimes were present in all samples studied.     

Maximum tensile properties of oriented polyethylene,achieved by uniaxial drawing of solution‐grown crystal mats: Effects of molecular weight and molecular weight distribution

The effects of molecular weight (MW) and MW distribution on the maximum tensile properties of polyethylene (PE), achieved by the uniaxial drawing of solution‐grown crystal (SGC) mats, were studied. The linear‐PE samples used had wide ranges of weight‐average (M_w = 1.5–65 × 10⁵) and number‐average MWs (M_n = 2.0–100 × 10⁴), and MW distribution (M_w/M_n = 2.3–14). The SGC mats of these samples were drawn by a two‐stage draw technique, which consists of a first‐stage solid‐state coextrusion followed by a second‐stage tensile drawing, under controlled conditions. The optimum temperature for the second‐stage draw and the resulting maximum‐achieved total draw ratio (DR_t) increased with the MW. For a given PE, both the tensile modulus and strength increased steadily with the DR_t and reached constant values that are characteristic for the sample MW. The tensile modulus at a given DR_t was not significantly affected by the MW in the lower DR_t range (DR_t < 50). However, both the maximum achieved tensile modulus (80–225 GPa) and strength (1.0–5.6 GPa), as well as those at higher DR_ts > 50, were significantly higher for a higher MW. Although the maximum modulus reached 225 ± 5 for M_n ≥ 4 × 10⁵, the maximum strength continued to increase with M_n even for M_n > 4 × 10⁵, showing that strength is more strongly dependent on the M_n, even at higher M_n. Furthermore, it was found that each of the maximum tensile modulus and strength achieved could be expressed by a unique function of the M_n, independently of the wide variations of the sample MW and MW distribution. These results provide an experimental evidence that the M_n has a crucial effect on the tensile properties of extremely drawn and chain‐extended PE fibers, because the structural continuity along the fiber axis increases with the chain length, and hence with the M_n. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 153–161, 2006     

Molecular weights and molecular weight distribution of polymers by equilibrium ultracentrifugation. Part II. Molecular weight distribution

A method has been developed for determining the molecular weight distribution of a polymer sample from the sedimentation–diffusion equilibrium data for a solution under pseudo-ideal conditions. From some theoretical examples it appears that the method works well and that the molecular weight distribution can be determined with a reasonable degree of resolution. From three polymer samples (polyethylene, polystyrene, and polycaprolactam) the molecular weight distribution was determined in this way. The average molecular weights, M?_n, M?_w, M?_z, and M _z+1, calculated from these distribution functions agree well with those calculated directly from the equilibrium data.     

Mechanical behavior of a highly oriented polyethylene rod

Dynamic mechanical and single step stress relaxation data are presented for a highly oriented linear polyethylene rod as produced by a high pressure extrusion technique. The results indicate that both major relaxation processes normally observed in unoriented polyethylene are virtually absent in torsion, whereas they are present in flexure. Stress relaxation in torsion data show a very highly nonlinear behavior when compared to similar data for an unoriented polyethylene rod.     

A fiber composite model of highly oriented polyethylene

A fiber composite model of highly drawn polyethylene is presented. Quantitative predictions and calculations are made using shear-lag theory. The drawing process is shown to occur in two stages, a neck and a postneck taper. It is shown that there is an empirical linear relationship, with a high correlation, between the parameter x in shear-lag theory (which involves the aspect ratio of the reinforcing elements and the square root of the ratio of matrix shear modulus to the Young's modulus of the reinforcing elements) and the 3/2 power of the taper draw ratio. It is concluded that crystalline fibrils (the reinforcing elements) deform homogeneously during the secondary, taper drawing process. The increase in aspect ratio resulting from this homogeneous deformation is held to be responsible for the increase in tensile modulus owing to the increased efficiency of the fibrils as reinforcing elements. The model is also used to explain the self-hardening process exhibited by these fibers and, using measurements of density of hardened fibers, to predict that immediately after the neck the aspect (length to diameter) ratio of the crystalline reinforcing elements is ca. 2 and that the shear modulus of the matrix material in as-drawn fibers is ～10³N/m² and does not change significantly during the taper-drawing process.     

Effect of molecular weight distribution on the structure and mechanical properties of ultradrawn,ultrahigh-molecular-weight polyethylene cast from solution. II. Drawability and mechanical properties

The effect of molecular weight distribution (MWD) on the ultradrawability and mechanical properties of solution-cast films of ultrahigh-molecular-weight polyethylene (UHMW-PE) has been investigated using tensile and dynamic mechanical measurements. The MWD has a marked effect on ultradrawability and thus on the ultimate mechanical properties such as the tensile modulus. It is proposed that UHMW-PE with a narrow MWD(N-PE) attains the ultimate structure at a lower draw ratio than UHMW-PE with a broad MWD(B-PE) because of the existence in the latter of less fully extended intercrystalline tie chains. It is found that, at the same drawing temperature (100°C), N-PE shows a higher modulus than B-PE at draw ratios up to 150 x, which is assumed to be the ultimate value for N-PE.     

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.     

Unexpected molecular weight dependence of shish-kebab structure in the oriented linear low density polyethylene/high density polyethylene blends

In this study, highly oriented shish-kebab structure was achieved via imposing oscillatory shear on the melts of linear low density polyethylene (LLDPE)/high density polyethylene (HDPE) blends during the packing stage of injection molding. To investigate the effect of molecular weight of HDPE on the formation of shish-kebab structure, two kinds HDPE with large melt flow index (low molecular weight) and small melt flow index (high molecular weight) were added into LLDPE matrix. The structural characteristics of LLDPE/HDPE blends were systematically elucidated through two-dimensional wide-angle x-ray scattering, scanning electron microscopy, and differential scanning calorimetry. Interestingly, an unexpected molecular weight dependence of shish-kebab structure of the prepared samples was found that the addition of HDPE with low molecular weight resulted in an higher degree of orientation, better regularity of lamellar arrangement, thicker lamellar size, and higher crystal melting temperature than that adding HDPE with high molecular weight. Correspondingly, the blend containing low molecular weight HDPE had better tensile strength. A possible mechanism was suggested to elucidate the role of HDPE molecular weight on the formation of shish-kebab structure in the oriented blends, considering the change of chain mobility and entanglement density with change of molecular weight.     

NMR study of molecular motion in oriented long-chain alkanes. II. Oriented mats of polyethylene single crystals

Measurements of the NMR second moment of a uniaxially oriented sample of polyethylene single crystals in the range of temperatures from ?196°C to 130°C and its dependence on the alignment angle γ between the orientation axis (preferential direction of the molecular chains) and the NMR magnetic field are presented. The experimental results are discussed mainly with respect to the high temperature relaxation, called the α process, in polyethylene. They are compared to theoretical predictions made for a number of mechanisms of molecular motion in Part I of this work. Only one of the mechanisms considered is found to be in quantitative agreement with experiment, the mechanism here referred to as flip-flop motion. This consists of thermally activated rotational jumps of the crystalline chain segment between folds around its axis between two equilibrium sites in the lattice. Each rotational jump through 180° is accompanied by a shift of the molecule along its axis by one CH₂ group. The discussion of the low-temperature relaxation of polyethylene, the γ process, is based partly on the above measurements and partly on measurements of second moments for unoriented polyethylene samples varying widely in morphology and noncrystalline content. The decrease of the second moment observed with these samples between ?196°C and 20°C is taken as a measure of the intensity of the γ process. A linear correlation is found between the decrease in the second moment, designated ΔS, and the noncrystalline content, 1 ? α_m; this can be represented by ΔS = 1.4 + 22.1(1 ? α_m). It is shown that neither the crankshaft mechanism not the kink mechanism is able to account quantitatively for this result. The model of a chain end moving in a vacancy fails to adequately describe the angle dependence of ΔS in oriented polyethylene single crystals. The “sandwich model” of a polyethylene single crystal, in which the crystalline core is covered by noncrystalline surface layers, is in better agreement with observations.     

Molecular weight distribution and molecular structure of polyethylene produced by radiation-induced polymerization

The molecular weight distribution of polyethylene produced by radiation was calculated according to a kinetic scheme. The calculated molecular weight distribution was compared with the results deduced from gel-permeation chromatography. The observed distribution curve from GPC was broader and showed a lower degree of polymerization than the calculated one. Discrepancies between observed and calculated curves can be explained if the polymer contains nonsteady-state products and if the reaction mechanism includes chain transfer to dead polymer. By this reaction long-chain branching would occur. Several long-chain branches per polymer molecule were indeed found, as inferred from solution properties.     

DSC ofγ-irradiated ultra-high molecular weight polyethylene and high density polyethylene of normal molecular weight

The melting and the crystallization of-irradiated (doses: 0–6Mrad) ultra-high molecular weight nascent polyethylene (UHMWPE) and high density nascent polyethylene with normal molecular weight (NMWPE) were investigated by DSC. The heat of melting of the nascent UHMWPE (DSC degree of crystallinity, respectively) increases up to a dose of 3 Mrad, after which it slightly decreases. The heat of the second melting of UHMWPE and of the first and second melting of NMWPE increases slightly up to a dose of 3 Mrad, after which it does not change. The X-ray degree of crystallinity of the nascent non-irradiated and irradiated polymers was 0.62±0.02. The calorimetric crystallinity was compared to the X-ray one. The results show that radiation does not affect the polymer crystallinity, but influences the thermodynamic heat of melting. The increase ofH _m vs. dose in UHMWPE is explained in terms of processes of tie molecule scission within the amorphous regions and on the surface of the crystals, which predominate over crosslinking up to a dose of 3 Mrad. That leads to an increase in the conformational mobility of the molecules and to an increase in the enthalpy, according to Peterlin's formula. The scission of the chains at the points of entangling of the tie molecules leads to a decrease in the temperature and to an increase in the enthalpy of crystallization of UHMWPE vs. dose. In NMWPE these effects are considerably weaker.     

Effect of molecular structure on polyethylene melt rheology. II. Shear-dependent viscosity

The investigation of the effect of molecular structural variables on the melt viscosity of polyethylene was extended to the shear dependent region by application of a reduced variables treatment following, in a formal sense, that of Bueche. Viscosity–shear rate data were obtained for a series of experimentally polymerized linear polyethylene samples having a range of molecular weights and molecular weight distributions as characterized primarily by gel permeation chromatography. These data could be superimposed on a single reduced variables flow curve using parameters which were a function only of temperature, limiting Newtonian viscosity, M?_w, and M?_w/M?_n. The same treatment was successfully applied also to branched (low-density) fraction data discussed in a previous paper, with additional correction for long-chain branching. However, different reduced variables curves were obtained for the branched and linear cases.     

Tensile strength of oriented polymers below the glass transition temperature

A theory of tensile strength, based on the observation of cracks in specimens strained to breaking, is formulated. The treatment involves the assumption that a crack grows to a critical size by a nucleation process. When this critical size is exceeded the crack becomes unstable and propagates spontaneously to produce rupture. By comparing the predicted and measured strength, one can estimate the magnitude of the stress concentration factor in fibers. An interpretative analysis of experimental data obtained at various strain rates indicates that the resulting changes in tensile strength are due primarily to the changes in modulus.     

Molecular weight distribution of emulsion-polymerized polyethylene

Emulsion polymerizations of ethylene were run using potassium persulfate as the initiator and either an anionic or a cationic surfactant, usually at five times the critical micellar concentration. The molecular weight distributions had at least two major peaks. The broadly distributed lower molecular weight component is formed in the early stages of polymerization. The higher molecular weight component has a narrow distribution characteristic of termination by the combination of chain radicals. The weight-average molecular weight of this component was about 400,000 when the surfactant was sodium laurate and 33,600,000 when the surfactant was dodecyl amine hydrochloride. © 1992 John Wiley & Sons, Inc.     

Tensile deformation of high strength and high modulus polyethylene fibers

The influence of tensile deformation on gel-spun and hor-drawn ultra-high molecular weight polyethylene fibers has been investigated. In high modulus polyethylene fibers no deformation energy is used to break chemical bonds during deformation, and flow is predominantly present next to elastic behavior. Flow is reversible after tensile deformation to small strains, but becomes irreversible when yielding occurs.Stress relaxation experiments were used to determine the elastic and flow contribution to tensile deformation. A simple quantitative relation could then be derived for the stress-strain curve that directly links yield stress to modulus. Experimental stress-strain curves could be reasonably described by this relation.Flow during tensile deformation is shown to be correlated with the introduction of the hexagonal phase in crystalline domains. A mechanism of flow is proposed in which, at first, tie molecules or intercrystalline bridges are pulled out of crystalline blocks (reversible), followed by the break-up of crystalline blocks through slip of microfibrils past each other (stress-induced melting, irreversible).     

Crystallization behavior of polylactide on highly oriented polyethylene thin films

The crystalline structure and morphology of the PLA crystallized isothermally from the glassy state on highly oriented PE substrates at 130℃were investigated by means of optical microscopy,AFM and X-ray diffraction.The results indicate that the PE substrate influences the crystallization behavior of PLA remarkably,which leads to the growth of PLA crystals on PE substrate always in edge-on form rather than the twisted lamellar crystals from edge-on to flat-on when crystallizing the PLA on glass surface under the same condition.The edge-on PLA lamellae on the PE substrate are preferentially arranged with their long axes in the chain direction of the PE substrate crystals.It is further demonstrated that except for the different crystal orientation,the PE does not influence the crystalline modification and crystallinity of the PLA.