Melt fracture behavior of polypropylene‐type resins with narrow molecular weight distribution. II. Suppression of sharkskin by addition of adhesive resins

Standing on a hypothesis that the sharkskin of a polymer with a narrow molecular weight distribution at extrusion processing originates from a stick‐slip of the polymer at the die wall, the suppression of the sharkskin was tried by means of suppressing the slip by the addition of adhesives. To polypropylene (PP)‐type resins with narrow molecular weight distributions such as a PP‐type thermoplastic elastomer, PER and a controlled rheology PP were added small amounts of adhesives such as maleated PP, maleated PER, reactive polyolefin oligomers, ethylene/ethylacrylate/maleic anhydride (MAH) copolymer, ethylene/vinyl acetate copolymer, and styrene/MAH copolymer, and their melt fracture behaviors at capillary extrusion were observed. It was found that the sharkskin of the PP‐type resins with narrow molecular weight distributions was suppressed by the addition of the adhesive resins with good adhesion to metal. The suppressive effect of the sharkskin was generally the more remarkable by the higher loading of the adhesives with the higher MAH content. This is the direction of increasing adhesion. From this fact, it was assumed that the sharkskin of the PP‐type resins with narrow molecular weight distribution does not originate from a periodic growth and relaxation of tensile stress at the extrudate surface but from a stick‐slip at the die wall. Based on this mechanism, it may be said that the sharkskin can be suppressed by both ways of directions of promoting and suppressing the slip at the die wall. The former way is the previously known method, and the latter way is the method proposed in the present study. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 2120–2127, 2002     

A study of extrudate distortion in controlled-rheology polypropylenes

The melt fracture characteristics of controlled-rheology polypropylenes (CRPP) were studied by means of capillary rheometry experiments. CRPPs were produced through reactive extrusion of a commodity polypropylene resin using various peroxide concentrations. These materials exhibited lower molecular weights and narrower molecular weight distributions than those of the starting commodity resin. The CRPP materials studied were found to exhibit only gross melt fracture. At extremely high shear rates and relatively low temperatures, a sigmoidal flexure was observed in the flow curve of certain CRPPs. Generally, it was found that the severity of melt fracture decreased with increasing shear rate for a given material and temperature and in some cases, the extrudates exhibited completely smooth surfaces. Also, the severity of surface distortions was reduced when high L/D dies were employed at a given shear rate. The critical shear stress for the melt fracture onset was found to increase with decreasing molecular weight and polydispersity, and correlations have been developed between the critical stress values and the polymer polydispersity and shear compliance.     

Shear‐induced β‐form polypropylene in long chain branching isotactic polypropylene

Long chain branching polypropylene (LCBPP) with different long chain branching (LCB) contents were prepared by reactive extrusion in the presence of styrene and benzoyl peroxide, and their shear‐induced crystallization behaviors were investigated. The results indicated that the LCB structure extended the relaxation time of LCBPP in the molten state, which led to the formation of β‐form polypropylene under shear and high cooling rate. The content of β‐form (K_β) increased with the increase of LCB content, shearing rate and cooling rate. The K_β value of LCBPP3 whose weight average molecular weight was 920,000 g mol^?1 could be up to 52.0% with a shear rate of 60 s^?1 associated with a cooling rate of 280°C min^?1. This study is expected not only to have a deeper understanding of the shear‐induced crystallization behavior of LCBPP, but also provide a new strategy to obtain high level β‐form polypropylene. POLYM. ENG. SCI., 56:240–247, 2016. © 2015 Society of Plastics Engineers     

Glass-fiber-reinforced polypropylene/EPDM blend. I. Melt rheological properties

Melt rheological properties of the blend of isotactic polypropylene (PP) and ethylene propylene diene rubber (EPDM) at varying ratios and of the glass fiber (GF) filled PP and PP/EPDM blend by varying both GF loading and blending ratio of the polyblend matrix are studied. Rheological measurements at 220°C in shear rate range 10¹?10⁴s^?1 were made on a capillary rheometer. Scanning electron micrographs of the extrudates are presented to show the morphology and the alignment of the glass fibers with respect to the flow direction. Variations of pseudoplasticity index, melt viscosity, and melt elasticity with EPDM content in PP/EPDM blend, and with varying GF content at any given composition of the matrix in PP/EPDM/GF ternary system, in the studied range are presented and discussed. Resultes on melt viscosity and melt elasticity show (i) reduced effect of GF at high shear rates on these properties and (ii) upward deviation of melt viscosity versus shear rate curve at low shear rates. A change in flow behavior in presence of GF is observed around a critical shear rate 2 × 10³ s^?1 and is attributed to the difference of interaction of GF and the dispersed rubber droplets at high and low shear rates. Elastic recovery showed nonequilibrium behavior at low shear rates.     

Rotating die technique for sharkskin minimization in highly viscous wood/PP composite melt in an extrusion die

This study used a newly developed rotating die system for purposes of reducing entrance pressure drop and sharkskin fracture for molten polypropylene (PP) and wood/polypropylene (WPP) composites in a single-screw extruder. The sharkskin fracture characteristics of the PP and WPP composite surfaces were examined quantitatively via roughness profiles and relaxation time evaluations, and qualitatively through scanning electron microscopy under the effects of wood content, shear rate, die temperature, and die rotation speed. The experimental results suggested that the entrance pressure drop of PP increased with increasing wood content and shear rate. The die entrance pressure drop for WPP composite melt with 30 wt % wood content could be minimized by 20–50% by using a die rotation speed of 70 rpm. The roughness level (sharkskin) and relaxation time were found to increase with increasing wood content, but could be minimized by rotating the die—the die rotating effect being more meaningful for WPP when compared with neat PP extrudate. The rotating die system was found to be an effective technique for minimizing the extrusion load and fracture level of extrudate skins for high-viscosity materials such as the WPP composites used in this work. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Comparisons of the rheological behaviors of polypropylene and polymethyl methacrylate in a capillary die

In this study, the rheological characteristics of polypropylene (PP) melt at 210, 220, and 230 °C and polymethyl methacrylate (PMMA) melt at 230, 240, and 250 °C in a micro die were investigated. The experiments were performed over a shear rate range of 3 × 10² to 5 × 10³ s^?1 using an advanced twin‐bore capillary rheometer. Dies with diameters of 1.0, 0.5, and 0.25 mm were used. The results indicated that the geometric dependences of the PP and PMMA viscosities were not identical at different shear rates and temperatures and that the micro size effect had a profound influence on the PP viscosity. The analysis demonstrated that the variations in the shear viscosity of the PP and PMMA melts in the micro die were partially attributed to the contribution of the pressure applied to the polymer melts. Additionally, the effect of wall slip on the PP and PMMA viscosities in the tested dies was investigated based on the modified Mooney method. The results implied that wall slip easily occurred in the PP melt flowing through the 0.25 mm die at 210 °C due to the distinct size effect. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134 , 44617.     

Rheological properties of poly(trimethylene terephthalate) in capillary flow

The shear viscosity, extensional viscosity, and die swell of the PTT melt were investigated using a capillary rheometer. The results showed that the PTT melt was a typical pseudoplastic fluid exhibiting shear thinning and extensional thinning phenomena in capillary flow. There existed no melt fracture phenomenon in the PTT melt through a capillary die even though the shear rate was 20,000 s^?1. Increasing the shear rate would decrease the flow activation energy and decline the sensitivity of the shear viscosity to the melt temperature. The molecular weight had a significant influence on the flow curve. The flow behavior of the PTT melt approached that of Newtonian fluid even though the weight‐molecular weight was below 43,000 s^?1 at 260°C. The extensional viscosity decreased with the increase of the extensional stress, which became more obvious with increasing the molecular weight. The sensitiveness of the extensional viscosity to the melt temperature decreased promptly along with increasing the extensional strain rate. The die swell ratio and end effect would increase along with increasing the shear rate and with decreasing the temperature, which represented that the increase of the shear rate and the decrease of temperature would increase the extruding elasticity of the PTT melt in the capillary die. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 705–709, 2005     

Preparation and properties of self-reinforced polypropylene/liquid crystalline polymer blends

The mechanical properties of self-reinforced liquid crystalline polymer/polypropylene (LCP/PP) blends strongly depend on the viscosity ratio of the blend components in the melt. This ratio was determined for PP blends with different commercial LCPs (Vectra A950 and Vectra B950), by means of capillary rheometry, under conditions representative for the blending process during extrusion. It was found that optimal mechanical properties were achieved when the LCP/PP viscosity ratio at 285°C ranges between 2 and 4 at a shear rate of 800–1000s⁻¹. The LCP/PP viscosity ratio appears to be shear stress dependent. This creates the option of fine tuning the LCP droplet deformation process by means of the extrusion rate. This shear stress dependence is more pronounced for PP blends with Vectra B950 than for blends with Vectra A950.     

UHMWPE/HDPE/纳米SiO2共混体系的毛细管挤出流变行为

采用毛细管流变仪,研究了超高分子量聚乙烯(UHMWPE)/高密度聚乙烯(HDPE)/纳米二氧化硅(SiO2)共混体系,及其对照组的流变行为和挤出过程中的不稳定流动现象,分析了共混物发生鲨鱼皮畸变和整体破裂的临界剪切应力和临界剪切速率的变化情况。结果表明,经过偶联剂改性的纳米SiO2粒子,在PE基质的共混体系中存在一定的界面黏附作用,降低了纳米共混体系的挤出胀大比,弹性特征减轻。这种界面相互作用限制了纳米共混材料在口模区域的黏性流动以及分子链离开口模后的构象恢复,降低了发生流动不稳定现象的临界剪切速率,发生鲨鱼皮畸变的临界剪切应力增大,整体破裂后,形成交替出现"鲨鱼皮-破裂"的振荡性变化外观。     

Comparison of superimposed effects in high‐shear‐rate capillary rheology of polystyrene,polypropylene, and linear low‐density polyethylene melts

Polymer melts exhibit unique rheological behaviors at high shear rate up to 10⁶ s^?1, which is a common phenomenon in micro‐injection molding. Both online and commercial capillary rheometers, which were modified to allow regulation of back pressure, were used for measuring the melt shear viscosities of polystyrene (PS), polypropylene (PP), and linear low‐density polyethylene (LLDPE) under high shear rates. The rheological characteristics of the three melts were compared through the systematical analyses for three significant effects, namely the end pressure loss, pressure dependence, and dissipative heating in capillary flow. Pronounced end effect begins to appear at the shear rates of 1.6 × 10⁵, 8.0 × 10⁵, and 2.8 × 10⁶ s^?1 for the PS, PP, and LLDPE melts, respectively. The significance of the end effect can be ordered as PS > PP > LLDPE. It seems that the polymers with more complex molecular structures exhibit a higher degree of divergence between the comprehensively corrected and uncorrected melt viscosity curves. Moreover, the dissipation effect begins to predominate over the pressure effect under the lowest shear rate of 10⁵ s^?1 for the PS melt among the three melts. POLYM. ENG. SCI., 55:506–512, 2015. © 2014 Society of Plastics Engineers     

Enhanced Solid Particle Erosion Properties of Thermoplastic Polyurethane‐Carbon Nanotube Nanocomposites

A co‐coagulation method combined with hot pressing technique is successfully applied to fabricate thermoplastic polyurethane (TPU) nanocomposites with different contents of carbon nanotubes (CNTs). Obviously, the mechanical and thermal properties of the nanocomposites are improved with increasing the CNT content. In addition, the existence of hydrogen bonding between CNTs and polymer matrix is demonstrated. Furthermore, the influences of impact parameters on solid particle erosion behavior are investigated systematically. The surface roughness and line roughness are also investigated to illustrate the mechanism of solid particle erosion. As elastic nanocomposites, the maximum and minimum erosion rate (ER) occur at 30° and 90°. The ER is relatively small when the impact velocity is at 10 m s^?1, then is increased rapidly between 20 and 30 m s^?1. As the size of impact particles increases to 300 µm, a rapid increase of ER occurs between 10 and 20 m s^?1. All these results indicate CNTs improve the erosion resistance of TPU matrix.     

Effect of acrylic acid neutralization on ‘livingness’ of poly[styrene‐ran‐(acrylic acid)] macro‐initiators for nitroxide‐mediated polymerization of styrene

BACKGROUND: The effect of acrylic acid neutralization on the degradation of alkoxyamine initiators for nitroxide‐mediated polymerization (NMP) was studied using styrene/acrylic acid and styrene/sodium acrylate random copolymers (20 mol% initial acrylate feed concentration) as macro‐initiators. The random copolymers were re‐initiated with fresh styrene in 1,4‐dioxane at 110 °C at SG1 mediator/BlocBuilder^® unimolecular initiator ratios of 5 and 10 mol%. RESULTS: The value of k_pK (k_p = propagation rate constant, K = equilibrium constant) was not significantly different for styrene/acrylic acid and styrene/sodium acrylate compositions at 110 °C (k_pK = 2.4 × 10^?6–4.6 × 10^?6 s^?1) and agreed closely with that for styrene homopolymerization at the same conditions (k_pK = 2.7 × 10^?6–3.0 × 10^?6 s^?1). All random copolymers had monomodal, narrow molecular weight distributions (polydispersity index M?_w/M?_n = 1.10–1.22) with similar number‐average molecular weights M?_n = 19.3–22.1 kg mol^?1. Re‐initiation of styrene/acrylic acid random copolymers with styrene resulted in block copolymers with broader molecular weight distributions (M?_w/M?_n = 1.37–2.04) compared to chains re‐initiated by styrene/sodium acrylate random copolymers (M?_w/M?_n = 1.33). CONCLUSIONS: Acrylic acid degradation of the alkoxyamines was prevented by neutralization of acrylic acid and allowed more SG1‐terminated chains to re‐initiate the polymerization of a second styrenic block by NMP. Copyright © 2008 Society of Chemical Industry     

Influence of rheological properties on the sagging of polypropylene and abs sheet for thermoforming applications

The isothermal sagging resistance of different grades of conventional and a high melt strength (HMS) PP has been correlated with the rheological characteristics of the polymers, such as dynamic shear properties, melt strength, and zero shear viscosity. A thermoforming grade of acrylonitrile‐butadiene‐styrene (ABS) was used as a reference material. At 190°C, ABS had the highest viscosity and elastic modulus in the frequency range measured, showing that this polymer is highly elastic. HMS PP had a greater shear thinning behavior than conventional PP because of its broader molecular weight distribution. The tan δ of the polymers showed that conventional PP had a higher tendency to flow than HMS PP and ABS when heated above 172°C. This was confirmed with sagging experiments performed in an air circulating oven, where the rate of sagging decreased as the melt strength and the zero shear viscosity of the polymer increased.     

The effect of side chains on the reactive rate and surface wettability of pentablock copolymers by ATRP

The reactive rate and surface wettability of three pentablock copolymers PDMS‐b‐(PMMA‐b‐PR)₂ (R = 3FMA, 12FMA, and MPS) obtained via ATRP for coatings are discussed. Poly(dimethylsiloxane) (PDMS) is used as difunctional macroinitiator, poly(methyl methacrylate) (PMMA) as the middle block, while poly(trifluoroethyl methacrylate) (P3FMA), poly(dodecafluoroheptyl methacrylate) (P12FMA) and poly(3‐(trimethoxysilyl)propyl methacrylate) (PMPS) as the end block, respectively. Their reactive rates obtained by gas chromatography (GC) analysis indicate that 3FMA gains 8.053 × 10^?5 s^?1 reactive rate and 75% conversion, higher than 12FMA (4.417 × 10^?5 s^?1, 35%), but MPS has 1.9389 × 10^?4 s^?1 reactive rate and 96% conversion. The wettability of pentablock copolymer films is characterized by water contact angles (WCA) and hexadecane contact angles (HCA). The PDMS‐b‐(PMMA‐b‐P12FMA)₂ film behaves much higher advancing and receding WAC (120° and 116°) and HCA (60° and 56°) than PDMS‐b‐(PMMA‐b‐P3FMA)₂ film (110° and 106° for WAC, 38° and 32° for HAC) because of its fluorine‐rich surface (20.9 wt % F). However, PDMS‐b‐(PMMA‐b‐PMPS)₂ film obtains 8° hysteretic contact angle in WAC (114°–106°) and HAC (32°–24°) due to its higher surface roughness (138 nm). Therefore, the fluorine‐rich and higher roughness surface could produce the lower water and oil wettability, but silicon‐rich surface will produce lower water wettability. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40209.     

Self‐assembly properties of ultra‐long‐chain gemini surfactant with high performance in a fracturing fluid application

A new cationic gemini surfactant (C25‐6‐C25), which had a special structure consisting of ultra‐long hydrophobic chains and amide groups, was synthesized using a main feedstock source obtained from rapeseed for thickening purposes. The 12 mmol L^?1 C25‐6‐C25 fluid containing 0.19 mol L^?1 potassium chloride (KCl) exhibited highly elastic properties at the angular frequency of 0.04–10 rad s^?1. Its viscosity could be maintained at 55 mPa s for 1.5 h under a shear rate of 170 s^?1 at 110 °C and it also showed a good proppant‐suspending property. C25‐6‐C25/KCl fluid exhibited high viscoelasticity and good performance, which were attributed to intermolecular forces, hydrogen bonding, and the shielding effect of electrostatic repulsion by KCl. Thus, C25‐6‐C25 is a very promising candidate for fracturing. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134 , 44602.     

Die‐swell behavior during the short‐tube flow of rubber compounds

In this study, the flow properties and die‐swell ratios (B's) of two kinds of rubber compounds (SI was a calcium carbonate filled natural rubber compound, and SII was a carbon‐black‐filled natural rubber/butadiene–styrene rubber/cis‐1,4‐butadiene rubber compound) in a short‐tube extrusion flow were measured by means of a capillary rheometer under test conditions with a temperature of 90°C and an apparent shear rate varying from 10 to 4000 s^?1 to identify the effects of extrusion conditions on the rheological behavior of the materials and to estimate B. The shear flow roughly obeyed the power law, whereas B increased nonlinearly with increasing extrusion rate. Under the same shear rates, the viscosity of SII was higher than that of SI, whereas the values of B of SI were higher than those of SII. Furthermore, B of the rubber compounds was estimated by means of an extrudate swell equation published in a previous work. The results show that the predictions of B were close to the measured data from the experiments. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Experimental investigation of the rheological behaviors of polypropylene in a capillary flow

The rheological characterization of polymer melts is strongly related to their material properties. In this study, we focused on the rheological behaviors of a polypropylene (PP) melt through a capillary die. With an advanced twin‐bore capillary rheometer with dies measuring 1.0, 0.5, and 0.25 mm in diameter, experiments were performed over a shear‐rate range of 3 × 10² to 5 × 10³ s^?1 at three temperatures, 210, 220, and 230 °C. The results demonstrate that the geometry dependence of the PP viscosity relied on the die diameter and the temperature of the PP melt. The viscosity values of the PP melt in the 0.25‐mm diameter die were higher than were those in the 0.5‐ and 1.0‐mm dies at 220 and 230 °C. However, the viscosity values in all of the tested dies were similar at 210 °C. The tendency for the viscosity to decrease as the temperature of the polymer melt increased weakened in the 0.25‐mm diameter die. As a result, the pressure applied to the PP melt in the 0.25‐mm diameter die increased; this caused a decrease in the free volume between molecules. On the basis of the Barus equation, the contribution of pressure to the changed viscosity in each die at each of the tested temperatures was calculated and was found to be as high as 32.86% in the 0.25‐mm die at 230 °C. Additionally, the effect of the wall slip on the geometry dependence of the PP viscosity in the tested dies was investigated with a modified Mooney method. The values of the slip velocity revealed that wall slip occurred only in the 0.25‐mm die at 210 °C. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43459.     

Novel processing aid based on modified Silly Putty®

A viscoelastic material based on low‐molecular‐weight silanols cured by boric acid, i.e., having a composition similar to that of the well‐known Silly Putty®, was used to delay sharkskin and stick–slip instabilities in the extrusion of linear low‐density polyethylene (LLDPE). The use of sodium hydroxide and phosphoric acid in the composition helped to improve adhesion of the material to metal and to extend its efficiency above 200°C. Adding powders of metal oxides, e.g., borax, silica, and especially silicates, further helped to delay the flow instabilities. A delay of the sharkskin instability to 25–35 times higher extrusion rates was achieved, and about 45% less pressure was observed in a screw extruder at the same throughput when this material was used as an additive to LLDPE (～0.1%) or as a coating of the extrusion die. Tentative explanations of the sharkskin origin and for the delay of the instability are proposed. J. VINYL. ADDIT. TECHNOL., 12:131–142, 2006. © 2006 Society of Plastics Engineers     

Chemorheological study of compatibilized blends of low‐density polyethylene and polydimethyl siloxane rubber

Compatibilization of the blends of polydimethyl siloxane (PDMS) rubber and low‐density polyethylene (LDPE) was achieved through reactive processing during extrusion in a Monsanto Processability Tester (MPT). The chemorheological characteristics of 50 : 50 LDPE : PDMS blends with varying proportions (0–8 wt %) of ethylene comethyl acrylate (EMA) were investigated at three different temperatures (170, 190, and 210°C) and four different shear rates (61.3, 122.6, 306.6, and 613.1 s^?1). It was found that EMA reacts with vinyl groups of PDMS rubber at a temperature of 190°C during extrusion through the capillary of MPT, forming EMA‐grafted‐PDMS rubber (EMA‐g‐PDMS), which acts as the compatibilizer for the blend systems. The results are based on IR spectroscopy, melt rheology, and phase morphology of the blends. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 12: 2810–2817, 2003     

Processability of LLDPE/LDPE blends: Capillary extrusion studies

The processing behavior of a number of linear low‐density polyethylenes/low density polyethylene (LLDPE/ LDPE) blends with emphasis on the effects of long chain branches is presented. A Ziegler‐Natta linear low‐density polyethylene was blended with four low‐density polyethylene LDPE's having distinctly different molecular weights. The weight fractions of the LDPEs used in the blends were 1, 5, 10, 20, 50, and 75 wt%. Capillary extrusion reveals that the onset of sharkskin and gross melt fracture are slightly influenced with the addition of LDPE into LLDPE. However, the amplitude of the oscillations in the stick‐slip flow regime was found to scale well with the weight fraction of LDPE. Amounts as low as 1 wt% LDPE have a significant effect on the amplitude of pressure oscillations. These effects are clearly due to the presence of long chain branching (LCB); furthermore, it was observed that the onset of this flow regime was shifted to higher shear rates with increase of LDPE content. On the other hand, shear rheology is not sensitive to detect addition of small levels of LDPE up to 20 wt%. Extensional rheology can detect levels of LDPE as small as 1 wt% only at high Hencky strain rates (typically greater than 5s^?1) and only for certain blends, typically those that contain LDPE of high molecular weight. It is suggested that the magnitude of oscillations in the oscillating melt fracture flow regime is a sensitive method capable of detecting low levels of LCB. POLYM. ENG. SCI., 47:1317–1326, 2007. © 2007 Society of Plastics Engineers