Rheological control in foaming polymeric materials: II. Semi-crystalline polymers

The influence of rheological properties and crystallization on foam structures, such as cell diameter, cell density and cell size distribution, of semi-crystalline polymer was investigated. The rheological properties of polypropylene (PP) were controlled by long chain branching (LCB) modification with free radical reaction and its crystallinity. The foaming behavior could be well correlated with the crystal structure and the rheological properties of polymers. The results showed that the long chain branching modification changed the crystallization speed, the diameter and the number of crystal and the rheological behavior as well. The interplay between the crystallization and the rheology of polymers with different chain structures can cause different nucleation mechanism in foaming. Both the cell size of linear PP and LCB PP decrease with crystallization time, and the cell density increases with crystallization time. The crystals in PPs acted as heterogeneous nucleation cites for bubbles, but the cell density of LCB PP is much higher than that of linear PP because of it higher spherulites density. The higher viscosity of branched PP further made its cell diameter smaller than that of linear one. Therefore, the foam structure can be well controlled by tuning the chain structure and crystal structures.     

Preparation and rheological characterization of long chain branching polylactide

Long chain branching (LCB) of polylactide (PLA) was successfully prepared by the successive reactions of PLA with pyromellitic dianhydride (PMDA) and 1,4-phenylene-bis-oxazoline (PBOZ) together. The topological structures of the LCB generated from functional group reactions were investigated thoroughly by gel permeation chromatography (GPC) and rheology. Qualitative information about the branching structures could be readily obtained from linear viscoelasticity, nonlinear oscillatory shear experiments and strain hardening in elongational experiments. For quantitative information on chain structure, linear viscoelasticity combined with branch-on-branch (BOB) dynamic model was used to predict probable compositions and chain topologies of the products, which were reasonably explained by the suggested mechanism of functional group reactions. It was found out that the star-like LCB structure generated in these reactions contributed remarkably to the enhancement of strain hardening under elongational flow.     

Long chain branching polylactide: Structures and properties

Long chain branching (LCB) of polylactide (PLA) was successfully prepared by the successive reactions of the end hydroxyl groups of PLA with pyromellitic dianhydride (PMDA) and triglycidyl isocyanurate (TGIC) together. The topological structures of the LCB generated from functional group reactions as well as free radical reactions were investigated thoroughly by gel permeation chromatography (GPC) and rheology. Qualitative information about the branching structures could be readily obtained from linear viscoelasticity, non-linear oscillatory shear experiments and strain hardening in elongational experiments. For quantitative information on chain structure, linear viscoelasticity combined with branch-on-branch (BOB) dynamic model was used to predict exact compositions and chain topologies of the products, which were reasonably explained by the suggested mechanism of functional group reactions. It was found out that the tree-like LCB structure generated in these reactions contributed remarkably to the enhancement of strain hardening under elongational flow, which improves the foaming ability substantially.     

Structure and melt rheology of long‐chain branching polypropylene/clay nanocomposites

Long‐chain branching polypropylene (LCB‐PP)/clay nanocomposites were prepared by melt blending in a twin‐screw extruder. The microstructure and melt rheology of these nanocomposites were investigated using x‐ray diffraction, transmission electron microscopy, oscillatory shear rheology, and melt elongation testing. The results show that, the clay layers are intercalated by polymer molecular chains and exfoliate well in LCB‐PP matrix in the presence of maleic anhydride grafted PP. Rheological characteristics, such as higher storage modulus at low‐frequency and solid‐like plateau in tan‐ω curve, indicate that a compact and stable filler network structure is formed when clay is loaded at 4 phr (parts per hundred parts of) or higher. The response of the nanocomposite under melt extension reveals an initial decrease in the melt strength and elongational viscosity with increasing clay concentration up to 6 phr. Later, the melt strength and elongational viscosity show slight increases with further increasing clay concentration. These results might be caused by a reduction in the molecular weight of the LCB‐PP matrix and by the intercalation of LCB‐PP molecular chains into the clay layers. Increases in the melt strength and elongational viscosity for the nanocomposites with decreasing extrusion temperature are also observed, which is due to flow‐induced crystallization under lower extrusion temperature. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Rheology and thermal behavior of long branching polypropylene prepared by reactive extrusion

Long‐chain branching polypropylene (LCB‐PP) was achieved by reactive extrusion in the presence of bifunctional monomer [1,6‐hexanediol diarylate (HDDA)] and peroxide of dicumyl peroxide (DCP). Influences of HDDA and DCP concentrations on the branching efficiency were comparatively evaluated. Fourier transformed infrared spectroscopy (FTIR) results indicated that the grafting reaction took place, and HDDA has been grafted on PP skeleton. In comparison with initial PP, some modified samples showed lower melt flow index because of a large number of LCB in their skeleton. Several rheology plots were used to investigate the rheological properties of the initial PP and modified PPs, and the rheological characteristics confirmed the LCB in modified PPs skeleton. DSC results showed that the crystallization temperatures of modified PPs were higher than those of initial PP and degraded PP, suggesting that the modified PPs had long‐chain branched structure. The contrastive investigation in the rheology of modified PPs suggested that proper concentrations of HDDA and DCP were more beneficial to producing LCB during reactive extrusion. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Processability of polyethylene homopolymers and copolymers with respect to their molecular structure

The processability of commercial polyethylene homopolymers and copolymers, including both high and low density polyethylenes, was evaluated with respect to their molecular structure by measuring their melt rheological and thermodynamic properties. Short chain branching (SCB) mainly controls the density and thermodynamic properties, but it has little effect on the melt rheological properties. Long chain branching (LCB) has little effect on the density and the thennodynamic porperties, but it has drastic effects on the melt rheological properties. LCB increases the pseudoplasticity and the flow activation energy, reducing the viscosity in processing and thus improving the processability. Very small amounts of LCB in metallocene type low density polyethylenes very effectively reduce the viscosity and improve the flow stability in processing.     

Effect of chain structure on the melt rheology of modified polypropylene

The effect of molecular structure of polypropylene (PP) on the melt rheological properties were investigated for electron irradiated polymer and di-2-ethylhexyl peroxy dicarbonate (EHPC)-treated polymer. The modifications were examined in terms of the rheological behaviors, molecular weight distribution, and the degree of branching. The high melt strength PP was obtained by irradiating with 50 and 80 kGy and adding EHPC. The modified PPs showed the strain hardening in the uniaxial elongational viscosity, though the linear elongational viscosity was lower than that of the unmodified PP. Low angle laser light-scattering measurements of the modified PPs showed the interesting results; high irradiation doses such as 50 and 80 kGy caused higher molecular weight chains branching. Nevertheless, the long branching chains were not detected for the EHPC modified PP, which also showed the strain hardening in uniaxial elongational flow. In this article, the relation between chain structure and rheological properties is discussed. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 73: 1493–1500, 1999     

Good extrusion foaming performance of long-chain branched PET induced by its enhanced crystallization property

Poly(ethylene terephthalate) (PET) was modified by regulating different contents of branching agent epoxy-based multifunctional oligomer and chain extender pyromellitic dianhydride in reactive extrusion process. The modified PET with better long-chain branched (LCB) structure boosted its rheological properties, and its enhancement of melt viscoelasticity resulted in excellent foamability in molten-state foaming process using supercritical CO₂ as blowing agent. More importantly, the branched structures acted as crystal sites to accelerate the crystallization kinetic of LCB PET whether under atmospheric pressure or high-pressure CO₂. The shear and elongation flow inside die further quickly induced the crystallization of LCB PET. The rapidly generated fine crystals could both introduce heterogeneous cell nucleation and suppress CO₂ escape, so the cell morphology of LCB PET in continuous extrusion foaming process exhibited a three-fold increase in cell density and smaller uniform cell size with respect to those of other foam-grade PET with long-chain structure.     

Control on the topological structure of polyolefin elastomer by reactive processing

The feasibility of preliminary tailoring of the long chain branched (LCB) polymer through complex flow field was evaluated in the torque rheometer, for the reaction of melt polyolefin elastomer (POE) with peroxides at elevated temperatures. With the compensation of temperature, the strength of complex shear flow could be the only factor affecting the reaction kinetics and mechanism. The results of sample characterization by the rheological and dilute polymer solution methods indicated that the degradation mainly made the length of LCB arm shorter and shorter as the rotational speed increases. Extremely, a certain amount of LCB degraded to be linear chains again due to the scission approaching the branching point at intense mixing condition. One new LCB index (D_LCB) was defined from nonlinear oscillatory shear, and a nearly linear relationship between it and long chain branching index (LCBI) was found, which can be a map to quantify LCB level by Fourier Transform Rheology (FTR).     

Long chain branched impact copolymer of polypropylene: Microstructure and rheology

A biphasic impact copolymer of polypropylene (ICP) was modified with peroxide by reactive extrusion process resulting in reduced melt flow index, improved melt strength, and higher die swell. The polymers were for the first time subjected to systematic rheological and microstructural characterization in an effort to understand their structure‐property relations. In shear rheological tests, the modified ICP displayed higher flow activation energy, reduced values of loss tangent and nearly equal frequency dependence of storage and loss modulli. The modified ICP also showed strain hardening behaviour in uniaxial extensional rheology and higher crystallization temperature in differential scanning calorimetry (DSC). All these are definitive indications of the presence of long chain branches (LCB). Fitting the rheological data of modified ICPs with the eXtended Pom Pom (XPP) model indicated the presence of LCB on the higher molecular weight fraction in the polymer, a result which was corroborated with multi‐detector high temperature gel permeation chromatography (HT‐GPC). More importantly, the matrix and rubber phases of the ICP were separately characterized for presence of long chain branching by rheology, DSC and HT‐GPC. The results indicate that while LCB existed in the matrix phase, microgels were present in both phases indicating that the reaction with peroxide occurred in both phases. POLYM. ENG. SCI., 55:1463–1474, 2015. © 2014 Society of Plastics Engineers     

The preparation and rheology characterization of long chain branching polypropylene

In order to study the rheological behavior of long chain branching (LCB) polypropylene (PP), linear polypropylene was modified by melt grafting reaction in the presence of 2,5-dimethyl-2,5(tert-butylperoxy) hexane peroxide and pentaerythritol triacrylate (PETA) in mixer. The transient torque curves and Fourier transformed infrared spectroscopy (FTIR) results indicated that macroradical recombination reactions took place and PETA had been grafted onto PP backbone. Various rheological plots including viscosity curve, storage modulus, loss angle, Han plot, Cole-Cole plot were used to distinguish LCB PP from linear PP. On the other hand, to quantify the LCB level in modified PPs, a new method was suggested on the basis of macromolecular dynamics models. The results showed that the level of LCB was in the range of 0.025-0.38/10⁴ C . Moreover, the length of the branched chains and the content of the branched component increase with PETA concentration. Furthermore, the LCB efficiency of monomer can also be calculated, less than 20% of grafting monomers was used to form branch structure.     

Characterization of electron beam irradiated polypropylene: Influence of irradiation temperature on molecular and rheological properties

The aim of the investigations was to analyze the influence of the temperature during the irradiation process of polypropylene on the molar mass, the formation of long chain branching and the final branching topology. A linear isotactic polypropylene homopolymer was modified by electron beam irradiation at different temperatures, with two irradiation doses to insert long chain branching. The samples were analyzed by size exclusion chromatography coupled with a multiangle laser light scattering detector, by differential scanning calorimetry, and by shear and elongational rheology. The shear and elongational flow behavior is discussed in terms of the influence of molecular parameters and used to analyze the topology of the irradiated samples. With increasing temperature, a slight reduction of the molar mass, an increase of long chain branching and an increase of crystallization temperature were found. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 2770–2780, 2006     

Shear and elongational rheology of polyethylenes with different molecular characteristics. II. Elongational rheology

The elongational viscosities of polyethylenes with different molecular characteristics were measured at different Hencky strains and temperatures with a capillary rheometer by the replacement of the capillary cylindrical die with a hyperbolic converging die. The hyperbolic shape of the die established a purely elongational flow field at a constant elongational strain rate throughout the die. The effects of molecular characteristics such as the molecular weight, molecular weight distribution, and long‐chain branching and processing conditions such as the temperature and Hencky strain on the elongational rheology of the polyethylene samples were studied. Good master curves were generated for temperature and Hencky strain shifting and simultaneous shifting with respect to both the temperature and Hencky strain. Both the molecular weight distribution and long‐chain branching seemed to promote strain rate thinning and reduce the elongational viscosity. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 1184–1194, 2007     

Chemical modification of PP architecture: Strategies for introducing long-chain branching

Two strategies for introducing long chain branching (LCB) to a polypropylene homopolymer (PP) are evaluated in terms of the product's molecular weight and branching distributions, and in terms of melt-state shear and extensional rheological properties. Single step processes involving radical-mediated addition of PP to triallyl phosphate are shown to generate bimodal products with highly differentiated chain populations, while a two step sequence involving PP addition to vinyltriethoxysilane followed by moisture-curing is shown to generate more uniform architectures. As a result, the sequential approach can improve low-frequency shear viscosity and extensional strain hardening characteristics while staying below the polyolefin's gel point. The composition and molecular weight distribution transformations that underlie sequential LCB techniques are discussed.     

The melt grafting preparation and rheological characterization of long chain branching polypropylene

To study the rheological properties of long chain branching (LCB) polypropylene (PP), long chain branches (LCB) were grafted onto the linear PP by melt grafting reaction in the presence of a novel chain extender, poly(hexamethylendiamine-guanidine hydrochloride) (PHGH). The branching reactions between the functionalized PP and PHGH were confirmed by transient torque curves and FTIR. By differential scanning calorimetry (DSC) and polarized microscope measurements, the presence of long chain branching structures was further confirmed. Also, the viscoelastic properties of the LCB PP and linear PP under shear flow were investigated for distinguishing LCB PP from linear PP. It was found that the elastic response of LCB PP at low frequencies was significantly enhanced in comparison with that of the linear PP, implying a presence of a long relaxation time mode that was not revealed in linear PP. Moreover, the branching levels of LCB PP were quantified using a detailed method, which was in correspondence with the molar amount of PHGH grafted on PP.     

The preparation and crystallization of long chain branching polylactide made by melt radicals reaction

Long chain branching (LCB) of polylactic acid (PLA) was successfully prepared by melt radicals reaction with pentaerythritol triacrylate (PETA) and bis (1‐methyl‐1‐phenylethyl) peroxide (DCP). The topological structure of the LCB was investigated by rheology and branch‐on‐branch (BOB) model was used to estimate the exact chain structures of the products, where comb‐like LCB structures were generated due to the complex coupling between different macro‐radicals. LCB structure was found to affect the crystallization of PLA products. In the temperature range of 110–130°C, the crystallization rate parameter (k) was improved sharply and the half crystallization time was decreased significantly after the grafting of PETA, which was ascribed to the enhanced hydrogen bonding in PETA‐grafted long chain branching PLA. By comparing with the LCB PLA made from chain extension using multifunctional monomer, it shows that the crystallization becomes slower in a highly branched material with extremely long relaxation time if the effect of hydrogen bonding is similar. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Upcycling of polypropylene with various concentrations of peroxydicarbonate and dilauroyl peroxide and two processing steps

The influence of two peroxides (peroxydicarbonate/dilauroyl peroxide) with various concentrations (10–200 mmol/kg PP) and their effective opportunity to introduce long chain branched (LCB) were investigated. The dependence of a single and double extrusion step and the changes of the properties were studied. Experiments were carried out in a single screw extruder at 180°C for the first extrusion step (modification) and at 240°C for the second extrusion step (processing simulation). Melt flow rate and dynamic rheological properties were studied at a measuring temperature of 230°C. For the definitive determination of long chain branched polypropylene (LCB-PP) served the extensional rheology measurements. The mechanical properties were examined via tensile test and impact tensile test. Summarized, LCB (melt strength) could be observed via extensional rheology for all modified specimens and the mechanical properties were maintained or even improved for the modified samples. Particularly, samples containing dilauroyl peroxide display excellent mechanical properties in this study.     

Methods of long chain branching detection in PE by triple‐detector gel permeation chromatography

Long chain branching (LCB) in polyethylene is one of the key microstructures that controls processing and final properties. Gel permeation chromatography (GPC) with viscometer (IV) and/or light scattering (LS) has been intensely used to quantify LCB. The widespread method to quantify LCB from GPC with IV or LS is the method of LCB frequency (LCBf) based on the Zimm–Stockmayer (ZS) random branching model. In this work, the conventional approach was compared with the recently developed method, called gpcBR. The comparison of the sensitivity of both methods is made on highly branched polymer, that is, various grades of commercial LDPE and also on polymer with very low level of LCB, that is, a commercial HDPE with no LCB, converted into several branched test samples of gradually increasing LCB by multiple extrusion. Finally, the linkages of LCB quantities from both methods to the rheological data and processing properties are illustrated. The new gpcBR index can access lower LCB level and shows obviously better relationship with both rheological data and processing properties than LCBf from the conventional ZS model. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42222.     

Properties of blends of linear and branched polypropylenes in film blowing

The effect of blending a long‐chain branched polypropylene (LCB‐PP) with a linear polypropylene (L‐PP) on the processability and properties of blown films was investigated. The rheological data revealed that blending an LCB‐PP with an L‐PP improved the elongational properties and the bubble stability, but a severe drop in the mechanical strength was observed for the blends. The most deteriorating effect was the reduction in the elongation at break in tensile tests carried out in the transverse direction (TD), where no yielding behaviour was observed for the blends.     

Effect of long‐chain branches of polypropylene on rheological properties and foam‐extrusion performances

The effect of modifying polypropylene by the addition of long‐chain branches on the rheological properties and performance of foam extrusion was studied. Three polypropylenes, two long‐chain‐branched polypropylenes and a linear polypropylene, were compared in this study. The modification was performed with a reactive‐extrusion process with the addition of a multifunctional monomer and peroxide. The rheological properties were measured with a parallel‐plate and elongational rheometer to characterize the branching degree. The change from a linear structure to a long‐chain‐branched nonlinear structure increased the melt strength and elasticity of polypropylene. Also, there was a significant improvement in the melt tension and sag resistance for branched polypropylenes. Foaming extrusion was performed, and the effect of the process variables on the foam density was analyzed with Taguchi's experimental design method. For this study, an L₁₈(2¹3⁵) orthogonal array was used on six parameters at two or three levels of variation. The considered parameters were the polypropylene type, the blowing agent type, the blowing agent content, the die temperature, the screw speed (rpm), and the capillary die length/diameter ratio. As a result, the most significant factor that influenced the foam density was the degree of long‐chain branching of polypropylene. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 96: 1793–1800, 2005