Microporous membranes of polyoxymethylene from a melt‐extrusion process: (I) effects of resin variables and extrusion conditions

A two‐part study utilizing polyoxymethylene (POM) was undertaken to investigate a three stage process (melt extrusion/annealing/uniaxial stretching) (MEAUS) employed to produce microporous films. In this first part, three POM resins (D, E, and F) were melt extruded into tubular films (blowup ratio; BUR = 1), where resin D has a higher weight average molecular weight (M_w) than resin E, but both possess similar and relatively narrow molecular‐weight distributions (MWD). In contrast, resin F is characterized by a distinctly broader MWD while its M_w is slightly higher than resin D. Specific attention was focused upon the morphological and crystal orientation results as a function MWD and M_w. A stacked lamellar morphology was obtained in each case from the melt extrusion; however, the type of stacked lamellar morphology, planar or twisted, and the orientation state was found to depend upon both the resin characteristics and the melt‐extrusion conditions. Atomic force microscopy and wide‐angle X‐ray scattering were the main techniques utilized to study the melt‐extruded films while dynamic melt rheometry in conjunction with the Carreau‐Yasuda model aided in differentiating the melt‐flow behavior of the three resins. Small‐angle light scattering (SALS) was also employed to characterize the morphological state. © 2001 John Wiley & Sons, Inc. J Appl Polym Sci 81: 2944–2963, 2001     

Molecular weight distribution of commercial PVC

The molecular weight distribution (MWD) of commercial suspension grade poly(vinyl chloride) (PVC) resins with K values from 50 to 93 and mass grade PVC resins with K values from 58 to 68 has been determined by size exclusion chromatography (SEC), using literature Mark‐Houwink coefficients. The MWD is characterized by the number average molecular weight (M_n), the weight average molecular weight (M_w) and the polydispersity (M_w/M_n). Our results for M_w are consistent with recently published data, but we find different results for M_n and consequently for M_w/M_n. The polydispersity of PVC increases with increasing K value. This effect can be explained by two mechanisms. The first mechanism is a reduced terminating reaction rate between two growing polymer chains (disproportionation) at higher molecular weight owing to the reduced mobility of the polymer chains. The second mechanism is long‐chain branching of molecules with high molecular weight which lets the molecules grow at two ends. For two examples graphs of the measured MWD are compared with the theoretically expected MWD.     

Flow properties of molten ethylene–vinyl acetate copolymer and melt fracture

In an investigation of the behavior and formation mechanism of melt fracture the flow properties of molten ethylene–vinyl acetate (EVA) copolymer in the region of high shear rate were measured with a capillary-type rheometer. EVA copolymer differs slightly in flow curve from low-density polyethylene (LDPE); it seems, however, that the difference is due to the difference in molecular weight distribution (MWD) rather than to the materials themselves. The fluidity of molten EVA copolymer having a narrow MWD is equivalent to that of LDPE having a broad MWD and, generally, EVA copolymer has a higher fluidity than LDPE. It is expected that the fluidity increases with incorporation of vinyl acetate at the same MWD and the same M?_w. The critical shear rate increases with melt index and temperature. It cannot be found that the materials themselves and the MWD directly influence the critical point of melt fracture formation when the melt index is taken as a parameter. The critical viscosity (η_c) at which melt fracture forms decreases in an almost straight line with an increase of melt index. It was found from the studies of end correction and behavior of melt fracture formation that melt fracture occurs at the inlet of the die, and it is supposed that the melt fracture formation is caused by the elastic turbulence in the flow pattern due to a failure of recoverable shear strain at the die inlet.     

Molecular characterization and rheological properties of modified poly(ethylene terephthalate) obtained by reactive extrusion

The use of a tetrafunctional epoxy‐based additive to modify the molecular structure of poly(ethylene terephthalate) (PET) was investigated with the aim of producing PET foams by an extrusion process. The molecular structure analysis and shear and elongation rheological characterization showed that branched PET is obtained for 0.2, 0.3 and 0.4 wt% of a tetrafunctional epoxy additive. Gel permeation chromatography (GPC) analysis led to the conclusion that a randomly branched structure is obtained, the structure being independent of the modifier concentration. The evolution of shear and extensional behavior as a function of molecular weight (M_w), degree of branching, and molecular weight distribution (MWD) were studied, and it is shown that an increase in the degree of branching and M_w and the broadening of the MWD induce an increase in Newtonian viscosity, relaxation time, flow activation energy and transient extensional viscosity, while the shear thinning onset and the Hencky strain at the fiber break decrease markedly.     

The influence of molecular weight distribution of industrial polystyrene on its melt extensional and ultimate properties

We analyze the linear viscoelastic behavior and the strain‐rate dependence of nonlinear viscoelastic as well as the ultimate extensional properties of industrially relevant linear polystyrene mixtures (PS). The studied materials comprise different miscible binary mixtures of a well entangled matrix and unentangled diluent resulting in bimodal molar mass distribution (MWD). We also analyze the effect of the diluent weight average molar mass (M_w) by comparison with a mixture having broad but monomodal MWD. We show that the dilution effect on linear rheological properties is in agreement with the theoretical value of unity for the dilution exponent. We further show that the processing window, expressed as the ability of the material to withstand a given load without loss of homogeneity during elongation or ultimate loss of cohesion, is affected differently depending on the diluent M_w and concentration. Finally, we conclude that the existence of strain hardening is not sufficient for complete characterization of extension dominated operations. Our results demonstrate that significant enhancement of strain hardening achieved by adding small‐M_w diluents is often accompanied by trade‐off with respect to failure behavior of these mixtures. POLYM. ENG. SCI. 56:1012–1020, 2016. © 2016 Society of Plastics Engineers     

Microporous membranes of isotactic poly(4‐methyl‐1‐pentene) from a melt‐extrusion process. I. Effects of resin variables and extrusion conditions

A study utilizing isotactic poly(4‐methyl‐1‐pentene) (PMP) was undertaken to investigate a three‐stage process (melt‐extrusion/annealing/uniaxial‐stretching) (MEAUS) employed to produce microporous films. The results of this study will be reported in the course of two articles. In this first part, three PMP resins were melt‐extruded into tubular films (blowup ratio; BUR = 1), where the resins each differ in weight‐average molecular weight (M_w). Specific attention was focused upon the morphological and crystal orientation results as a function of the melt‐relaxation times as influenced by the resin characteristics and the processing parameters. The results of a number of melt‐extrusion conditions are presented. A stacked lamellar morphology was obtained in each case; however, the type of stacked lamellar morphology, planar or twisted, and the orientation state was found to depend upon both the resin characteristics, specifically M_w, and the melt‐extrusion conditions. Atomic force microscopy and wide‐angle X‐ray scattering (WAXS) were the main techniques utilized to study the melt‐extruded films, while oscillatory shear measurements, in conjunction with a Carreau–Yasuda analysis, aided in differentiating the melt‐flow behavior of the three resins. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 83: 2095–2113, 2002     

Extrusion of broad‐molecular‐weight‐distribution polyethylenes

The extrusion (single‐screw) characteristics of four high‐molecular‐weight, broad‐molecular‐weight‐distribution (MWD) polyethylene resins are discussed with an emphasis on the output rate. Despite the high molecular weights of the subject polyethylenes, their broad MWD (M_w/M_n range: 10 to 50) does not limit the pressure and torque developed during extrusion. However, the specific output of the four polymers was quite varied. First, the dynamics of the solids conveying section were examined with the highest‐molecular‐weight polyethylene exhibiting lower solids‐conveying rate than the other three. Further, a simple and quick method to evaluate the relative solids‐conveying efficiencies for various polyethylenes is presented. Finally, the dependence of the specific output on the melt rheology of the polymers is also addressed; specifically, the shear‐thinning extent of the melt in the metering section was found to influence output rate. The unique and counterintuitive temperature‐dependence of the shear‐thinning character for one of the four polymers will also be addressed in relation to its extrusion characteristics. Polym. Eng. Sci. 44:2266–2273, 2004. © 2004 Society of Plastics Engineers.     

Rheological properties of polypropylenes with different molecular weight distribution characteristics

Relationships between the rheological properties and the molecular weight distribution of two polypropylene series with different molecular weight distribution characteristics were studied. The end correction coefficient in capillary flow is determined by the molecular weight M_w and the molecular weight distribution M_w/M_n, and is higher as both characteristic values are larger. The die swell ratio at a constant shear rate depends on M_w, M_w/M_n, and M_z/M_w, and is higher as the three characteristic values are larger. The critical shear rate at which a melt fracture begins to occurs depends on the molecular weight M_w and the molecular weight distribution M_z/M_w, and is proportional to M_z/M_w² in a log–log plot. The critical shear stress does not depend on the molecular weight, and is higher as M_z/M_w is higher. The zero‐shear viscosity is determined by a molecular weight of slightly higher order than M_w, and the characteristic relaxation time is determined by M_z. The storage modulus at a constant loss modulus scarcely depends on the molecular weight, and is higher as the molecular weight distribution M_w/M_n is higher. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 2128–2141, 2002     

The viscoelastic properties of rubber–resin blends. II. The effect of resin molecular weight

In blends of rubber and low molecular weight resins, the compatibility of the system controls the viscoelastic properties and ultimately the performance of the composition as a pressure sensitive adhesive. The effect of the resin molecular weight on compatibility was examined by studying rubber–resin blends prepared from resins which represent a range of molecular weights. Viscoelastic properties were measured using a mechanical spectrometer on 1:1 blends of rubber and a series of polystyrene resins and poly(vinylcyclohexane) resins. Based on plots of G′ and tan δ vs. temperature, blends of natural rubber and polystyrene resin show incompatibility at resin M_w of about 600 and above. Blends of natural rubber and poly(vinyl cyclohexane) are incompatible at resin M_w of about 1800, but are compatible at M_w of about 650. Blends of styrene–butadiene rubber and polystyrene resins are compatible at resin M_w of about 650 but appear to contain a low volume incompatible phase at M_w of about 900. Therefore, the compatibility of a rubber–resin blend depends upon the molecular weight of the resin. Even systems expected to be compatible will show evidence of incompatibility as the molecular weight of the resin is raised above some limiting value.     

Optimal temperature for the control of the product quality in batch polymerization: Simulation and experimental results

A method to determine an optimal temperature profile that guarantees products having controlled molecular weight distribution (MWD) and desired values of molecular weight (M_w) is presented. The base case is the batch polymerization of MethylMethAcrylate, initiated by AIBN. On the basis of the kinetic model, the optimal temperature profile is determined by imposing that the value of the instantaneous chain length is maintained constant, thus counteracting the effects of the increase of viscosity, which leads to broad MWD. Some approximations permit to express, in a straightforward way, the relationship between the optimal temperature and the conversion as a function of the initial conditions. The validity of the simplifying hypotheses that have been assumed is confirmed first by simulation results and then by a comparison with experimental runs conducted in a labscale unit, with determination of MWD made by means of GPC. The obtained results suggest that it is possible to decouple the problem: acting on the operating temperature to control the MWD, acting on initial temperature and initiator concentration to influence the M_w. The possibility of application to industrial reactors has also been investigated, taking into account their peculiarities and constraints. © 1995 John Wiley & Sons, Inc.     

Head to head polymers IX: The rheological behavior of H-H and H-T atactic polystyrenes

The rheological behavior of a sample of H-H polystyrene of M_n of 41,000 and a M_w/M_n of 2 was compared at 160 and 190°C with a sample of H-T atactic polystyrene of similar molecular weight. The melt viscosity of H-H polymer (unlike the H-T polymer) was non-Newtonian at low stresses and decreased more rapidly with stress. This observation seems to indicate a stiffer polymer chain for the H-H polystyrene. The flow activation energy (E*) of H-H polystyrene was found to be dependent on the dynamic shear stress and decreased with increasing dynamic shear stress. The dynamic shear storage modulus of the H-H polymer has a smaller increase of G′ with ω than that of the H-T polystyrene.     

Rheological and mechanical properties of recycled polypropylene

In order to verify the possibility of manufacturing good quality articles by recycled polypropylene (PP), a study on the effect of many recycling operations on the rheological and mechanical properties of PP was conducted. The amount of degradation occurring during the reprocessing was estimated in the melt state by means of rheological measurements and the results obtained were correlated with the weight average molecular weight M_w and the molecular weight distribution MWD. Since the properties in the solid state are strictly dependent upon the molecular structure parameters and the morphology, mechanical properties were checked on films produced from virgin and recycled PP with a cast technology. Moreover, in order to estimate the effect of film composition and of the number of reprocessings on the final properties of the manufactured articles, blend films having different percentages of PP recycled several times and virgin PP were prepared.     

Prediction of high density polyethylene processing behavior from rheological measurements

In order to predict the processing behavior of a high density polyethylene resin one must know the resin flow behavior over a wide range of shear rates. Low shear properties are important in applications where melt strength, sagging, etc. are critical. On the other hand, high shear flow properties are a determining factor in applications where melt instability, melt fracture and heat generation are important. The flow behavior of a resin can be established by measuring the zero shear viscosity, η₀, the maximum relaxation time, τ₀, and the shape of the flow curve. We have measured these basic rheological parameters on a large number of high density polyethylene resins. A shear sensitivity parameter which is independent of molecular weight was derived from a correlation between η₀ and τ₀. This parameter, together with η₀, provide the vital information needed in order to predict the processing behavior of the resin. This method is applicable to other polymer systems provided that the rheological parameters η₀ and τ₀ can be experimentally obtained.     

Chemical modification of poly(1-butene) resins through reactive processing

Controlled-rheology poly(1-butene) resins have been produced by chemical modification of commodity poly(1-butene) (PB-1) resins through reactive processing with an organic peroxide. Using various amounts of peroxide, samples have been produced and have been analyzed in terms of their molecular and rheological properties. Molecular weight distributions (MWD) as determined by gel permeation chromatography (GPC) indicate that polydispersity (PDI) remains approximately constant but weight-average molecular weight (M_w) decreases with increasing peroxide concentration. These trends are in agreement with predictions from a kinetic model previously developed for the production of controlled-rheology polypropylene. Linear viscoelastic measurements indicate that the modified samples are thermorheologically simple and that zero-shear viscosity decreases with increasing peroxide concentration while flow activation energy remains approximately constant. Finally, no significant variation in melting and crystallization properties was observed for the range of peroxide concentrations used. Based on these results, it is proposed that tailor-made controlled-rheology poly(1-butene) resins can be produced easily through reactive extrusion operations similar to those used for the production of controlled-rheology polypropylene (CRPP).     

Effect of molecular weight and molecular weight distribution on the rheological properties of aqueous poly(ethylene oxide) solution

The effect of the molecular weight and the molecular weight distribution on the rheological properties of aqueous poly(ethylene oxide) (PEO) solutions has been investigated with four PEO samples differing in their M_w, M_w/M_n and purity. The main result of this study is that the steady shear viscosity as well as the complex dynamic viscosity of the samples with broad molecular weight distribution greatly differed from the viscosities of the samples having a narrow molecular weight distribution. Furthermore, the samples with broad molecular weight distribution showed a distinct molecular weight dependent non-Newtonian behavior at increasing shear rates and frequencies. This behavior was not observed for the sample with a narrow molecular weight distribution. Both effects are mainly attributed to the influence of the high molecular weight fraction in the PEO samples of broad molecular weight distribution. The often reported degradation of PEO solutions was not observed within the time scale of our experiment.     

Experimental investigation of flow induced molecular weight fractionation during extrusion of HDPE polymer melts

In this work, two different HDPEs with virtually identical number, M_n, and weight, M_w, average molecular weights were investigated from rheological as well as die drool phenomenon point of view. It has been revealed that long-chain branching, low polymer melt elasticity and shear viscosity significantly reduce die drool phenomenon at the die exit region. It has been concluded that die drool phenomenon of HDPE polymer melts can be explained by the flow induced molecular weight fractionation.     

Rheological characteristics of hyperbranched polyesters

Summary When the effects of physical aging below T _g are erased, the rheological response of a series of aliphatic hyperbranched polyesters is Newtonian and the melt viscosity scales roughly linearly with M _w at high M _w, indicating entanglement to be absent. The rheological behavior is also highly sensitive to the nature of the terminal groups, suggesting the overall behavior to be close to that of an assembly of compact coreshell "particles". There are therefore strong parallels between the physical behavior of the hyperbranched polyesters in question and that of their ideal dendrimer analogues. Received: 14 April 2002 /Revised: 1 July 2002 / Accepted: 1 July 2002     

Effects of molecular weight and molecular weight distribution on creep properties of polypropylene homopolymer

The molecular weights of the industrial-grade isotactic polypropylene (i-PP) homopolymers samples were determined by the melt-state rheological method and effects of molecular weight and molecular weight distribution on solid and melt state creep properties were investigated in detail. The melt-state creep test results showed that the creep resistance of the samples increased by M_w due to the increased chain entanglements, while variations in the polydispersity index (PDI) values did not cause a considerable change in the creep strain values. Moreover, the solid-state creep test results showed that creep strain values increased by M_w and PDI due to the decreasing amount of crystalline structure in the polymer. The results also showed that the amount of crystalline segment was more effective than chain entanglements that were caused by long polymer chains on the creep resistance of the polymers. Modeling the solid-state viscoelastic structure of the samples by the Burger model revealed that the weight of the viscous strain in the total creep strain increased with M_w and PDI, which meant that the differences in the creep strain values of the samples would be more pronounced at extended periods of time.     

Synthesis and characterization of emulsion copolymer of N‐cyclohexylmaleimide and methyl methacrylate

Copolymers of N‐cyclohexylmaleimide (ChMI) and methyl methacrylate (MMA) were synthesized by the emulsion semibatch copolymerization method. The effects of the monomer mixture composition on the average molecular weight (M_n and M_w ), glass transition temperature (T_g), degradation temperature, mechanical properties, and rheological behavior of the copolymers were investigated. The results show that M_n and M_w have maximum values when the ChMI feed content was about 20% (by wt). The degradation temperature and T_g of the copolymers increase with increasing ChMI moieties in the copolymer. The mechanical properties (tensile strength and impact strength) decrease with an increasing ChMI feed content. All copolymers in the melt show pseudoplastic behavior. The flow index n increases with an increasing ChMI feed content. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 1070–1075, 2002; DOI 10.1002/app.10394