Flow-induced shish-kebab precursor structures in entangled polymer melts

Stretching-Regulated Homogenization of Lamellae Thickness in Biaxially Oriented Polypropylene Capacitor Films, and Its Effect on Breakdown Strength

Stretching fields give rise to the formation of reinforcing crystals in biaxially oriented polypropylene capacitor films, endowing them with excellent electrical properties. In this paper, the correlation between stretching temperature, ratio, and annealing temperature and film structure as well as electric breakdown strength (Eb) during biaxial stretching is investigated. Synchronous biaxial stretching ensures that the orientation of the prepared films is isotropic. However, the changes caused by the stretching field occur in the lamellae structure, with a gradation of thick and thin lamellae. First, an increasing stretching ratio leads to the homogenization of the crystal toward thick lamellae, increasing Eb. Second, the onset melting temperature (Tonset) is the key to the gradation of thick and thin lamellae. Stretching near or above Tonset results in a reduced order of the recrystallization precursors and forms thin lamellae, degrading Eb. Additionally, annealing below the melting point promotes chain migration, which facilitates the homogenization to thick lamellae and improves Eb. In conclusion, the improvement of Eb is related to the homogenization of lamellae thickness. These results provide new insights for optimizing film processing and crystal structure to enhance electrical insulation.

Chain-Level Analysis of Reinforced Polyethylene through Stretch-Induced Crystallization

Herein, we propose a large-scale simulation approach to perform the stretch-induced crystallization of entangled polyethylene (PE) melts. Sufficiently long (1000 ns) united-atom molecular dynamics (UAMD) simulations for 16000 chains of 1000 consecutive CH2 united-atom particles under periodic boundary conditions were performed to achieve the crystallinity observed in experiments. Before the isothermal crystallization process, we applied uniaxial stretching as pre-elongation to the embedded strain memory on the entangled PE melts. We confirmed significant differences in the morphologies of crystal domains and scattering patterns for pre-elongation ratios of 400% and 800%. The obtained scattering patterns were consistent with the experimental results. Uniaxial stretching MD simulations revealed that the elastic modulus at 800% pre-elongation was stronger than that at 400% pre-elongation. From this observation, we can derive the structure-property relationship, wherein the magnitude of the pre-elongation governs the crystal domain structures and mechanical properties.

Achieving High-Performance Green Composites from Pineapple Leaf Fiber-Poly(butylene succinate) through Both Fiber Alignment and Matrix Orientation across the Thickness

This research aims to develop high-performance and low-carbon composites using biobased poly(butylene succinate) (PBS) reinforced with well-aligned pineapple leaf fibers (PALF). PBS/PALF composites containing 10 and 20% PALF by weight (wt %) were prepared using a two-roll mill. During the mixing process, the molten material was slightly stretched to align the fibers in the machine direction, forming a uniaxial prepreg. The prepreg was subsequently stacked and compressed into composite sheets at compression temperatures of 120 and 140 °C. Differential scanning calorimetry, X-ray diffraction, and crystalline morphology analysis revealed the presence of matrix orientation in the prepreg, which was preserved in sheets compressed at 120 °C but not at 140 °C. The composites prepared at 120 °C exhibited significantly higher flexural strength and modulus compared to those prepared at 140 °C, attributed to the combined effect of matrix and PALF orientation. Additionally, the composites displayed an increase in heat distortion temperature, with a maximum of 10 °C higher than the matrix melting temperature (∼113 °C) for the composite with 20 wt % PALF. These findings indicate the potential for increased utilization of this low-carbon green composite.

Methanol-Assisted ADMET Polymerization of Semiaromatic Amides

A method for the acyclic diene metathesis polymerization of semiaromatic amides is described. The procedure uses second-generation Grubbs' catalyst and N-cyclohexyl-2-pyrrolidone (CHP), a high boiling, polar solvent capable of solubilizing both monomer and polymer. The addition of methanol to the reaction was found to significantly increase polymer molar mass although the role of the alcohol is currently not understood. Hydrogenation with hydrogen gas and Wilkinson's catalyst resulted in near-quantitative saturation. All polymers synthesized here exhibit a hierarchical semicrystalline morphology driven by ordering of aromatic amide groups via strong nonbonded interactions. Furthermore, the melting points can be tuned over a >100 °C range by precise substitution at just one of the backbone positions on each mer (<5% of the total).

Atomistic Simulation of Flow-Induced Microphase Separation and Crystallization of an Entangled Polyethylene Melt Undergoing Uniaxial Elongational Flow and the Role of Kuhn Segment Extension

Atomistic simulations of the linear, entangled polyethylene C₁₀₀₀H₂₀₀₂ melt undergoing steady-state and startup conditions of uniaxial elongational flow (UEF) over a wide range of flow strength were performed using a united-atom model for the atomic interactions between the methylene groups constituting the polymer macromolecules. Rheological, topological, and microstructural properties of these nonequilibrium viscoelastic materials were computed as functions of strain rate, focusing on regions of flow strength where flow-induced phase separation and flow-induced crystallization were evident. Results of the UEF simulations were compared with those of prior simulations of planar elongational flow, which revealed that uniaxial and planar flows exhibited essentially a universal behavior, although over strain rate ranges that were not completely equivalent. At intermediate flow strength, a purely configurational microphase separation was evident that manifested as a bicontinuous phase composed of regions of highly stretched molecules that enmeshed spheroidal domains of relatively coiled chains. At high flow strength, a flow-induced crystallization (FIC) occurred, producing a semicrystalline material possessing a high degree of crystallinity and primarily a monoclinic lattice structure. This FIC phase formed at a temperature (450 K) high above the quiescent melting point (≈400 K) and remained stable after cessation of flow for temperature at or below 435 K. Careful examination of the Kuhn segments constituting the polymer chains revealed that the FIC phase only formed once the Kuhn segments had become essentially fully extended under the UEF flow field. Thermodynamic properties such as the heat of fusion and heat capacity were estimated from the simulations and found to compare favorably with experimental values.

Nanoconfined Crystallization in Poly(lactic acid) (PLA) and Poly(ethylene terephthalate) (PET) Induced by Various Forms of Premelt-Deformation

The processing-structure-property relationship using poly(lactic acid) (PLA) and poly(ethylene terephthalate) (PET) is explored. Specifically, both pre-extension and preshear of amorphous PLA and PET above their glass transition temperatures T_g , carried out in the affine deformation limit, can induce a specific type of cold crystallization during annealing, i.e., nanoconfined crystallization (NCC) where crystal sizes are limited to a nanoscopic scale in all dimensions so as to render the processed PLA and PET optically transparent. The new polymer structure after premelt deformation can show considerably enhanced mechanical properties. For example, premelt stretching produces geometric condensation of the chain network. This structural alternation can profoundly change the mechanical characteristics, e.g., turning brittle PLA ductile. In contrast, after preshear of amorphous PLA above T_g , the NCC containing PLA remains brittle, showing the importance to have geometric condensation from processing. Both AFM imaging and SAXS measurements are performed to verify that premelt deformation of PLA and PET indeed results in NCC from annealing that permits the strain-induced cold crystallization to take place on the length scale of the mesh size of the deformed chain network.

Morphology of Shear-Induced Polymer Cylindrites Revealed by 3D Optical Imaging

Two-photon confocal laser microscopy was used to obtain three-dimensional (3D) images of the morphology of poly(lactic acid) after shear-induced crystallization. The necessary fluorescence contrast was achieved by doping the polymer with Nile Red. The dye gets partially rejected from the growing crystalline aggregates during their formation, thus creating a renderable high-low fluorescence boundary outlining the shape of the aggregates. Parallel-plate melt-shearing and pulling a glass fiber through the melt were used as the two methods to achieve shear-induced crystallization. This study focuses on the shape of the resulting cylindrites, i.e., large-diameter shish-kebabs. The first 3D images of polymer cylindrites show that, if far from boundaries, they are circular cylinders, highly regular after fiber pull, but less so after parallel-plate shear. In the latter case, the cylindrite reveals the trajectory of the foreign particle that had nucleated its growth. Interestingly, lateral growth of the cylindrites was found to accelerate toward the sample surface when approaching it, giving the cylindrite an elliptical cross section. Furthermore and surprisingly, in the case of fiber pull, a row of spherulites is nucleated at the polymer-substrate interface nearest to the fiber, aligned along the fiber axis and appearing ahead of the rest of the space-filling spherulites. Both the phenomena, elliptical cylindrites and row of spherulites, are attributed to negative pressure buildup peaking at the cylindrite growth front and at the nearby film surface caused by crystallization-induced volume contraction. The pressure and flow distribution in the system is confirmed by numerical simulation. The results illustrate the value of 3D imaging of crystalline morphology in polymer science and polymer processing industry.

Effects of Machine Washing on the Chromatography Parameters of Polyester Fiber Gel Permeation

Fiber examination is frequently performed in forensics, and gel permeation chromatography (GPC) is one candidate method for discriminating polyester fibers. Here, the effects of machine washing on weight-average molecular weight (M w), polydispersity index (PDI), and the percentage peak area of cyclic ethylene terephthalate trimer (PPAL) of commercial polyester shirts and manufactured poly(ethylene terephthalate) (PET) yarns were investigated using GPC. GPC was performed using a 1,1,1,3,3,3-hexafluoro-propan-2-ol polymer solubilizer, styrene-divinylbenzene copolymer GPC columns, a chloroform mobile phase, and a 254 nm absorbance monitor. The statistical change in the polyester fibers during machine washing was evaluated by comparing three GPC parameters of the same fiber samples before and after machine washing. Among the commercial polyester shirts examined, the GPC parameters changed significantly after machine washing with a considerable PPAL decrease. In contrast, the GPC parameters of manufactured PET yarns changed significantly with a moderate increase in M w. This work elucidates the change on GPC parameters of polyester fibers by machine washing.

Experiments and Modeling of Flow-Enhanced Nucleation in LLDPE

A computational and experimental framework for quantifying flow-enhanced nucleation (FEN) in polymers is presented and demonstrated for an industrial-grade linear low-density polyethylene (LLDPE). Experimentally, kinetic measurements of isothermal crystallization were performed by using fast-scanning calorimetry (FSC) for melts that were presheared at various strain rates. The effect of shear on the average conformation tensor of the melt was modeled with the discrete slip-link model (DSM). The conformation tensor was then related to the acceleration in nucleation kinetics by using an expression previously validated with nonequilibrium molecular dynamics (NEMD). The expression is based on the nematic order tensor of Kuhn segments, which can be obtained from the conformation tensor of entanglement strands. The single adjustable parameter of the model was determined by fitting to the experimental FSC data. This expression accurately describes FEN for the LLDPE, representing a significant advancement toward the development of a fully integrated processing model for crystallizable polymers.

Polymer crystallization under external flow

The general aspects of polymer crystallization under external flow, i.e., flow-induced crystallization (FIC) from fundamental theoretical background to multi-scale characterization and modeling results are presented. FIC is crucial for modern polymer processing, such as blowing, casting, and injection modeling, as two-third of daily-used polymers is crystalline, and nearly all of them need to be processed before final applications. For academics, the FIC is intrinsically far from equilibrium, where the polymer crystallization behavior is different from that in quiescent conditions. The continuous investigation of crystallization contributes to a better understanding on the general non-equilibrium ordering in condensed physics. In the current review, the general theories related to polymer nucleation under flow (FIN) were summarized first as a preliminary knowledge. Various theories and models, i.e., coil-stretch transition and entropy reduction model, are briefly presented together with the modified versions. Subsequently, the multi-step ordering process of FIC is discussed in detail, including chain extension, conformational ordering, density fluctuation, and final perfection of the polymer crystalline. These achievements for a thorough understanding of the fundamental basis of FIC benefit from the development of various hyphenated rheometer, i.e., rheo-optical spectroscopy, rheo-IR, and rheo-x-ray scattering. The selected experimental results are introduced to present efforts on elucidating the multi-step and hierarchical structure transition during FIC. Then, the multi-scale modeling methods are summarized, including micro/meso scale simulation and macroscopic continuum modeling. At last, we briefly describe our personal opinions related to the future directions of this field, aiming to ultimately establish the unified theory of FIC and promote building of the more applicable models in the polymer processing.

Molecular dynamics simulations of the effects of carbon nanotube content on stretch-induced crystallization of polyethylene/carbon nanotube nanocomposites

In the present work, we used molecular dynamics simulations to study the effects of carbon nanotube (CNT) content on stretch-induced crystallization behaviors in CNT filled polyethylene systems. During high-temperature stretching,...

Extrusion and Injection Molding of Poly(3-Hydroxybutyrate-co-3-Hydroxyhexanoate) (PHBHHx): Influence of Processing Conditions on Mechanical Properties and Microstructure

Biobased and biodegradable polyhydroxyalkanoates (PHAs) have great potential as sustainable packaging materials. However, improvements in their processing and mechanical properties are necessary. In this work, the influence of melt processing conditions on the mechanical properties and microstructure of poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBHHx) is examined using a full factorial design of experiments (DoE) approach. We have found that strict control over processing temperature, mold temperature, screw speed, and cooling time leads to highly increased elongation at break values, mainly under influence of higher mold temperatures at 80 °C. Increased elongation of the moldings is attributed to relaxation and decreased orientation of the polymer chains together with a homogeneous microstructure at slower cooling rates. Based on the statistically substantiated models to determine the optimal processing conditions and their effects on microstructure variation and mechanical properties of PHBHHx samples, we conclude that optimizing the processing of this biopolymer can improve the applicability of the material and extend its scope in the realm of flexible packaging applications.

Shear-Induced Crystallization of Star and Linear Poly(L-lactide)s

The influence of macromolecular architecture on shear-induced crystallization of poly(L-lactide) (PLLA) was studied. To this aim, three star PLLAs, 6-arm with Mw of 120 and 245 kg/mol, 4-arm with Mw of 123 kg/mol, and three linear PLLAs with Mw of 121, 240 and 339 kg/mol, were synthesized and examined. The PLLAs were sheared at 170 and 150 °C, at 5/s, 10/s and 20/s for 20 s, 10 s and 5 s, respectively, and then cooled at 10 or 30 °C/min. Shear-induced crystallization during cooling was followed by a light depolarization method, whereas the crystallized specimens were examined by DSC, 2D-WAXS, 2D-SAXS and SEM. The effect of shear depended on the shearing conditions, cooling rate and polymer molar mass but it was also affected by the macromolecular architecture. The shear-induced crystallization of linear PLLA with Mw of 240 kg/mol was more intense than that of the 6-arm polymer with similar Mw, most possibly due to its higher Mz. However, the influence of shear on the crystallization of the star polymers with Mw close to 120 kg/mol was stronger than on that of their linear analog. This was reflected in higher crystallization temperature, as well as crystallinity achieved during cooling.

Elucidating the Opportunities and Challenges for Nanocellulose Spinning

Man-made continuous fibers play an essential role in society today. With the increase in global sustainability challenges, there is a broad spectrum of societal needs where the development of advanced biobased fibers could provide means to address the challenges. Biobased regenerated fibers, produced from dissolved cellulose are widely used today for clothes, upholstery, and linens. With new developments in the area of advanced biobased fibers, it would be possible to compete with high-performance synthetic fibers such as glass fibers and carbon fibers as well as to provide unique functionalities. One possible development is to fabricate fibers by spinning filaments from nanocellulose, Nature's nanoscale high-performance building block, which will require detailed insights into nanoscale assembly mechanisms during spinning, as well as knowledge regarding possible functionalization. If successful, this could result in a new class of man-made biobased fibers. This work aims to identify the progress made in the field of spinning of nanocellulose filaments, as well as outline necessary steps for efficient fabrication of such nanocellulose-based filaments with controlled and predictable properties.

Thermal Stability and Nucleation Efficacy of Shear-Induced Pointlike and Shishlike Crystallization Precursors

The different thermal stabilities of shear-induced pointlike and shishlike crystallization precursors of polyamide 11, generated in a parallel-plate rheometer and coexisting in the same sample, were quantified by hot-stage microscopy, by performing self-seed crystallization experiments. Crystals formed at low supercooling of the melt from these different types of precursors melt at about the same temperature. Annealing of the melt at different temperatures for a predefined time revealed dissolution/disordering of these precursors at 10-15 K higher temperature, near the equilibrium melting point. Despite their similar thermal stabilities, pointlike and shishlike crystallization precursors exhibit distinctly different nucleation efficacies. Under identical crystallization conditions, shishlike precursors cause faster crystallization than pointlike crystal nuclei. The faster crystallization of the shishlike nuclei can be explained, for example, by (a) the larger size of the shishlike precursors, providing numerous nucleation sites; (b) the more perfect chain conformation at the shish surface, which serves as a substrate for crystallization; or perhaps (c) the higher local orientation of the surrounding melt compared with molecular segments near pointlike nuclei, reducing the activation energy for crystallization.

Inducing nano-confined crystallization in PLLA and PET by elastic melt stretching

Based on the widely studied poly(l-lactic acid) (PLLA) and polyethylene terephthalate (PET) that are brittle in their fully crystalline form, this Letter shows that they can be made to be super ductile, heat resistant and optically clear by creating nano-sized crystals while preserving the entanglement network. Atomic force microscopic images confirm the perceived nano-confined crystallization. Time-resolved X-ray scattering/diffraction measurements reveal the emergence of cold crystallization during either stress relaxation from large stepwise melt-stretching or annealing of pre-melt-stretched PLLA and PET above Tg. Mechanical tests show that these polymers in such a new state are rigid even well above Tg, e.g., at 100 °C.

Revealing the detailed structure in flow-induced crystallization of semicrystalline polymers

We systematically investigate the detailed structure in the flow-induced crystallization of a lightly cross-linked high-density polyethylene as a model semicrystalline polymer sample by combining the small-angle X-ray scattering (SAXS) and the spherical harmonic expansion (SHE) method. The SHE divides the two-dimensional SAXS pattern into several components according to the deformation geometry, and allows extraction of the most relevant information. Employing the first two anisotropic components in the expansion and a comprehensive model, we determine the crystalline morphological parameters, such as the long period, the lamellar diameter and thickness, and their polydispersities. In particular, we find that the lamellar diameter exhibits bimodal distributions at high strains. Lamellae with similar diameters tend to gather rather than to randomly distribute with others, suggesting the existence of heterogeneity in the semicrystalline structure. Moreover, we observe the strong polydispersities of the lamellar structure at low strains. The structural heterogeneity and polydispersities could be related to the inhomogeneities in crystal growth and nucleation processes.

Unique Slow Crack Growth Behavior of Isotactic Polypropylene: The Role of Shear Layer-Spherulites Layer Alternated Structure

With the development of polymer science, more attention is being paid to the longevity of polymer products. Slow crack growth (SCG), one of the most important factors that reveal the service life of the products, has been investigated widely in the past decades. Here, we manufactured an isotactic polypropylene (iPP) sample with a novel shear layer–spherulites layer alternated structure using multiflow vibration injection molding (MFVIM). However, the effect of the alternated structure on the SCG behavior has never been reported before. Surprisingly, the results showed that the resistivity of polymer to SCG can be enhanced remarkably due to the special alternated structure. Moreover, this sample shows unique slow crack propagation behavior in contrast to the sample with the same thickness of shear layer, presenting multiple microcracks in the spherulites layer, which can explain the reason of the resistivity improvement of polymer to SCG.

Flow-Induced Crystallization in Polyethylene: Effect of Flow Time on Development of Shish-Kebab

The flow-induced formation and relaxation of the representative oriented shish-kebab structure were studied with synchrotron small-angle X-ray scattering (SAXS) method. The flow duration was varied from 2 to 6 s at an identical strain rate to reveal the effect of flow time on stability and dimension of formed shish. It was found that the short flow time of 2 s was able to generate shish during flow, which, however, relaxed during the isothermal process after cessation of flow. An increase in flow time can improve the shish stability and the long flow time of 6 s can generate the stable shish that nucleate the growth of kebab lamellae. In addition, the quantitative analysis of SAXS results showed that with increasing flow time from 2 to 6 s, the shish length increased from 242 to 574 nm, while the shish diameter remained around 34 nm. This detailed information of the formed shish-kebab structure can be used to shed light on their evolution that occurred during flow from 2 to 6 s, where shish grew at a longitudinal speed of around 80 nm/s, and there was an improvement in the stability and nucleation capability for kebab lamellae.