The functions of crystallizable ethylene‐propylene copolymers in the formation of multiple phase morphology of high impact polypropylene

The functions of crystallizable ethylene‐propylene copolymers in the formation of multiple phase morphology of high impact polypropylene (hiPP) were studied by solvent extraction fractionation, transmission electron microscopy (TEM), selected area electron diffraction (SAED), nuclear magnetic resonance (¹³C‐NMR), and selected reblending of different fractions of hiPP. The results indicate that hiPP contains, in addition to polypropylene (PP) and amorphous ethylene‐propylene random copolymer (EPR) as well as a small amount of polyethylene (PE), a series of crystallizable ethylene‐propylene copolymers. The crystallizable ethylene‐propylene copolymers can be further divided into ethylene‐propylene segmented copolymer (PE‐s‐PP) with a short sequence length of PE and PP segments, and ethylene‐propylene block copolymer (PE‐b‐PP) with a long sequence length of PE and PP blocks. PE‐s‐PP and PE‐b‐PP participate differently in the formation of multilayered core‐shell structure of the dispersed phase in hiPP. PE‐s‐PP (like PE) constructs inner core, PE‐b‐PP forms outer shell, while intermediate layer is resulted from EPR. The main reason of the different functions of the crystallizable ethylene‐propylene copolymers is due to their different compatibility with the PP matrix. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Crystallization and melting behaviour of polypropylene ‘catalloys’

The crystallization and melting behaviour of polypropylene ‘catalloys’ (PP‐cats) as well as pure polypropylene (PP) were investigated using differential scanning calorimetry. The results showed that, for PP‐cats and PP, a single melting peak of PP appeared under slow cooling rate. When the cooling rate is fast enough in the non‐isothermal case, or the crystallization temperature is relatively high in the isothermal case, a shoulder peak appears in front of the melting peak with increasing ethylene content in PP‐cats. It is believed that this shoulder is induced by recrystallization of crystals initially formed during non‐isothermal or isothermal crystallization. When the ethylene component in PP‐cats reached a certain level, there existed a melting peak of polyethylene (PE) crystallized during the cooling process. Polarized optical microscopy (POM) showed that the spherulites formed by PP‐cats were much smaller and had less perfect morphology compared with that formed by pure PP at the same cooling rate. And with the increase of the cooling rate, the spherulites could not be clearly observed. Copyright © 2004 Society of Chemical Industry     

Effect of self‐nucleation on crystallization and melting behavior of polypropylene and its copolymers

The effect of self‐nucleation on the crystallization and melting behavior of isotactic polypropylene (i‐PP) and low ethylene content propylene–ethylene copolymers were investigated. Isothermal crystallization kinetics were studied using the Avrami equation and Lauritzen‐Hoffman nucleation theory. It was found that self‐nucleation can enhance the crystallization. The surface free energy ς_e decreased for the self‐nucleated sample. The melting behavior was affected by the preselected temperature, T_s, at which the polymer was partially melted. © 1999 John Wiley & Sons, Inc. J Appl Polym Sci 72: 1559–1564, 1999     

Structure and morphology of polyethylene/polypropylene in‐reactor alloys synthesized by spherical high‐yield Ziegler–Natta catalyst

A series of spherical polyethylene/polypropylene (PE/PP) in‐reactor alloys were synthesized with spherical high‐yield Ziegler–Natta catalyst by sequential multistage polymerization in slurry. The morphology of PE/PP alloy granule was evaluated by optical microscopy, scanning electron microscopy, and transmission electron microscopy. The results show PE/PP in‐reactor alloy with excellent morphology, high porosity, and narrow distribution of the particle size. The PE/PP in‐reactor alloys show excellent mechanical properties with good balance between toughness and rigidity. It was fractionated into five fractions by temperature‐gradient extraction fractionation, and every fractionation was analyzed by FTIR, ¹³C‐NMR, DSC, and WAXD. The PE/PP in‐reactor alloy was found to contain mainly five portions: PP, PE, segmented copolymer with PP and PE segment of different length, ethylene‐b‐propylene copolymer, and an ethylene–propylene random copolymer. The characteristic chain structure leads to good compatibility between the fractions of the alloy that shows a multiphase structure. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 2075–2085, 2007     

Effect of the structure on the morphology and spherulitic growth kinetics of polyolefin in‐reactor alloys

Four polyolefin in‐reactor alloys with different compositions and structures were prepared by sequential polymerization. All the alloys were fractionated into five fractions: a random copolymer of ethylene and propylene (25°C fraction), an ethylene–propylene segmented copolymer (90°C fraction), an ethylene homopolymer (110°C fraction), an ethylene–propylene block copolymer (120°C fraction), and a propylene homopolymer plus a minor ethylene homopolymer of high molecular weight (>120°C fraction). The effect of the structure on the morphology and spherulitic growth kinetics of the polypropylene (PP) component in the alloys was investigated. The polyolefin alloys containing a suitable block copolymer fraction and a larger amount of PP had a more homogeneous morphology, and the crystalline particles were smaller. Quenching the polyolefin alloys led to smaller crystallites and a more homogeneous morphology as well. Isothermal crystallization was carried out above the melting temperature of polyethylene, and the growth of PP spherulites was monitored with polarized optical microscopy with a hot stage. The alloys with higher propylene contents exhibited a faster spherulitic growth rate. The fold surface free energy was derived, and it was found that a large amount of block copolymer fractions and random copolymer fractions could reduce the fold surface free energy. The structure of the alloys also affected the crystallization regime of PP. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 98: 632–638, 2005     

Influence of copolymerization conditions on the structure and properties of polyethylene/polypropylene/poly(ethylene‐co‐propylene) in‐reactor alloys synthesized in gas‐phase with spherical ziegler‐natta catalyst

A spherical TiCl₄/MgCl₂‐based catalyst was used in the synthesis of polyethylene/polypropylene/poly (ethylene‐co‐propylene) in‐reactor alloys by sequential homopolymerization of ethylene, homopolymerization of propylene, and copolymerization of ethylene and propylene in gas‐phase. Different conditions in the third stage, such as the pressure of ethylene–propylene mixture and the feed ratio of ethylene, were investigated, and their influences on the compositions, structural distribution and properties of the in‐reactor alloys were studied. Increasing the feed ratio of ethylene is favorable for forming random ethylene–propylene copolymer and segmented ethylene–propylene copolymer, however, slightly influences the formation of ethylene‐b‐propylene block copolymer and homopolyethylene. Raising the pressure of ethylene–propylene mixture results in the increment of segmented ethylene–propylene copolymer, ethylene‐b‐propylene block copolymer, and PE fractions, but exerts a slight influence on both the random copolymer and PP fractions. The impact strength of PE/PP/EPR in‐reactor alloys can be markedly improved by increasing the feed ratio of ethylene in the ethylene–propylene mixture or increasing the pressure of ethylene–propylene mixture. However, the flexural modulus decreases as the feed ratio of ethylene in the ethylene–propylene mixture or the pressure of ethylene–propylene mixture increases. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 2481–2487, 2006     

Influence of polymerization conditions on the structure and properties of polyethylene/polypropylene in‐reactor alloy synthesized in the gas phase with a spherical Ziegler–Natta catalyst

A spherical TiCl₄/MgCl₂‐based catalyst was used in the synthesis of in‐reactor polyethylene/polypropylene alloys by polyethylene homopolymerization and subsequent homopolymerization of propylene in the gas phase. Different conditions in the ethylene homopolymerization stage, such as monomer pressure and polymerization temperature, were investigated, and their influences on the structure and properties of in‐reactor alloys were studied. Raising the polymerization temperature is the most effective way of speeding up polymerization and regulating the ethylene content of polyethylene (PE)/polypropylene (PP) alloys, but it will cause a greater increase in the PE‐b‐PP block copolymer fraction (named fraction D) than in the fraction of PP‐block‐PE in which the PP segments have low or medium isotacticity (named fraction A). Although changing ethylene monomer pressure could influence the ethylene content of PE/PP alloys slightly, it is an effective way of regulating the structural distribution. Reducing the monomer pressure will evidently increase fractions A and D. The mechanical properties of the alloys, including impact strength and flexural modulus, can be regulated in a broad range with changes in polymerization conditions. These properties are highly dependent on the amount, distribution, and chain structure of fractions A and D. The impact strength is affected by both fraction A and fraction D in a complicated way, whereas the flexural modulus is mainly determined by the amount of fraction A. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 2136–2143, 2006     

Study on thermal behavior of impact polypropylene copolymer and its fractions

An impact polypropylene copolymer (IPC) was fractionated into three fractions using n‐octane as solvent by means of temperature‐gradient extraction fractionation. The glass transitions, melting, and crystallization behavior of these three fractions were studied by modulated differential scanning calorimeter (MDSC) and wide‐angle X‐ray diffraction (WAXD). In addition, successive self‐nucleation and annealing (SSA) technique was adopted to further examine the heterogeneity and the structure of its fractions. The results reveal that the 50°C fraction (F₅₀) mainly consists of ethylene‐propylene random copolymer and the molecular chains may contain a few of short but crystallizable propylene and/or ethylene unit sequences; moreover, the lamellae thicknesses of the resulting crystals are extremely low. Furthermore, 100°C fraction (F₁₀₀) mainly consist of some branched polyethylene and various ethylene‐propylene block copolymers in which some ethylene and propylene units also randomly arrange in certain segments, and some polypropylene segments can form crystals with various lamellae thickness. An obvious thermal fractionation effect for F₁₀₀ samples after being treated by SSA process is ascribed to the irregular and nonuniform arrangement of ethylene and propylene segments. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Fractionation and characterization of an ethylene–propylene copolymer produced with a MgCl2/SiO2/TiCl4/diester‐type ziegler–natta catalyst

An ethylene–propylene copolymer synthesized with a Ziegler–Natta catalyst was fractionated by a combination of dissolution/precipitation and temperature‐gradient extraction fractionation. The fractions were characterized with ¹³C‐NMR, differential scanning calorimetry, and wide‐angle X‐ray diffraction. The fractionation was carried out mainly with respect to the content of ethylene, but the crystallizable propylene sequences could also exert an influence on the fractionation. The copolymer contained a series of components with wide variations in the compositions. With an increase in the ethylene content, the structure of the fractions became blockier and blockier, and the fraction extracted at 111°C had the blockiest structure. A further increase in the ethylene content led to a decrease in the length and number of the propylene sequences. Differential scanning calorimetry results showed that the composition distribution in single fractions was not homogeneous, and multiple melting peaks were observed. Wide‐angle X‐ray diffraction results revealed both polyethylene and polypropylene crystals in most of the fractions. Short propylene sequences could be included in the polyethylene crystals, and short ethylene sequences could also be incorporated into the polypropylene crystals. The incorporation of propylene sequences into polyethylene crystals strongly depended on the sequence distribution and crystallization conditions. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Compositional differences of propylene–ethylene block copolymers manufactured by degradation and hydrogenation techniques

The purpose of the present work is to investigate the compositional difference of polypropylene–polyethylene block copolymers (PP‐b‐PE) manufactured industrially by the process of degradation and hydrogenation, respectively. Each of the PP‐b‐PE copolymers was fractionated into three fractions with heptane and chloroform. The compositions of the three fractions were characterized by ¹³C nuclear magnetic resonance (NMR) and Fourier transform infrared (FTIR) spectroscopy, as well as differential scanning calorimetry (DSC) and thermal fractionation. The results showed that the Chloroform‐soluble fraction was amorphous ethylene‐propylene rubber, and the content of the rubber in PP‐b‐PE manufactured by hydrogenation was less than that by degradation. The degree of crystallinity of the chloroform‐insoluble fraction of the PP‐b‐PE manufactured by hydrogenation is higher than that of by degradation. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 3301–3306, 2006     

Characterization and crystallization behavior of poly(ethylene‐co‐trimethylene terephthalate) copolymers

A series of poly(ethylene‐co‐trimethylene terephthalate) (PETT) copolymers were prepared by polycondensation. The synthesized PETT are block copolymers and the content of poly(trimethylene terephthalate) (PTT) units incorporated into the copolymers are always larger than that fed in the polymerization. The nonisothermal crystallization at the different cooling rates was studied by means of differential scanning calorimetry. The copolymers develop the crystallization later and show the lower melting temperature than the corresponding enriched homopolymers. The modified Avrami analysis fit well the nonisothermal crystallization of these polymers. The overall rate of crystallization of PTT is fastest and that of PET is slowest, whereas the copolymers are between them at the same cooling rate. The minor PET units incorporated into PTT polymer chains reduce the crystallization of PTT segments, but the present minor PTT units in the PET chains seem to accelerate the crystallization of PET segments. The Avrami exponent nvaries in the range of 3 – 4, indicating that the nonisothermal crystallization follows the homogeneous nucleation and two‐ to three‐dimensional growth mechanism. Wide angle X‐ray diffraction analysis explains that the PET and PTT units do not cocrystallize and it is considered as the enriched polymer segments to crystallize during crystallization. POLYM. ENG. SCI., 2008. © 2008 Society of Plastics Engineers     

Chain structure of polyethylene/polypropylene in‐reactor alloy synthesized in gas phase with spherical Ziegler–Natta catalyst

Two polyethylene/polypropylene (PE/PP) in‐reactor alloy samples were synthesized by multi‐stage gas‐phase polymerization using a spherical Ziegler–Natta catalyst. The alloys show excellent toughness and stiffness. FTIR, ¹³C‐NMR and thermal analysis proved that the alloys are mainly composed of polyethylene, PE‐block‐PP copolymer and polypropylene. There are also a few percent of ethylene‐propylene segmented copolymer with very low crystallinity. The block copolymer fraction accounts for more than 25 % of the alloy. The role of the block copolymer as compatibilizer between PE and PP is believed to be the key factor that results in the excellent toughness–stiffness balance of the material. Copyright © 2004 Society of Chemical Industry     

Chain structure and mechanical properties of polyethylene/polypropylene/poly(ethylene‐co‐propylene)in‐reactor alloys synthesized with a spherical Ziegler–Natta catalyst by gas‐phase polymerization

Two polyethylene/polypropylene/poly(ethylene‐co‐propylene) in‐reactor alloy samples with a good polymer particle morphology were synthesized by sequential multistage gas‐phase polymerization with a spherical Ziegler–Natta catalyst. The alloys showed excellent mechanical properties, including both toughness and stiffness. With temperature‐gradient extraction fractionation, both alloys were fractionated into five fractions. The chain structures of the fractions were studied with Fourier transform infrared, ¹³C‐NMR, and thermal analysis. The alloys were mainly composed of polyethylene, polyethylene‐b‐polypropylene block copolymer, and polypropylene. There also were minor amounts of an ethylene–propylene segmented copolymer with very low crystallinity and an ethylene–propylene random copolymer. The block copolymer fraction accounted for more than 44 wt % of the alloys. The coexistence of these components with different structures was apparently the key factor resulting in the excellent toughness–stiffness balance of the materials. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 97: 640–647, 2005     

Thermal behaviour of polyethylene‐block‐poly(methyl methacrylate) block copolymer: effect of multiple heating and cooling rates versus mathematical artefact

The melting and crystallization behaviours of a polyethylene‐block‐poly(methyl methacrylate) (PE‐b‐PMMA) diblock copolymer and a PE homopolymer were investigated using multiple heating and cooling rate differential scanning calorimetry (DSC) experiments, and modelling of the crystallization kinetics and lamellar thickness distribution. This new model was first validated applying literature and experimental data. The model‐predicted morphology (n = 3.2) closely matched the spherulitic morphology (n = 3), which was determined using polarized optical microscopy. For each experimental cooling rate, the model predicted diblock copolymer crystallinity that well matched the entire DSC crystallinity curve, notably for an Avrami–Erofeev index of n = 2; and apparent crystallization activation energy that hardly varied with the cooling rates used, relative crystallinity (α), and crystallization temperature or time. This disfavours the concept of variable activation energy. The use of the right crystallization model and parameter estimation algorithm is important for addressing the mathematical artefact. Under non‐isothermal cooling, the PE‐b‐PMMA diblock copolymer, as per the model prediction, crystallized without confinement (n ≠ 1), preserving the cylindrical structure. From the characteristic shapes of the crystallization function f(α(T)) versus 1/T and crystallization rate versus α plots, the resulting T_cmax and narrow α_max range can guide the search for an appropriate crystallization model. The overall treatment illustrated in this study is not restricted to a PE homopolymer and a PE‐b‐isotactic PMMA block copolymer. It can be generally applied to crystalline homopolymers and copolymers (alternating, random and block), as well as their blends. The block copolymers and blends can be crystalline–amorphous as well as crystalline–crystalline. © 2014 Society of Chemical Industry     

Melting behavior and isothermal crystallization kinetics of PP/mLLDPE blends

The melting/crystallization behavior and isothermal crystallization kinetics of polypropylene (PP)/metallocene-catalyzed linear low density polyethylene (mLLDPE) blends were studied with differential scanning calorimetry (DSC). The results showed that PP and mLLDPE are partially miscible and interactions mainly exist between the mLLDPE chains and the PE segments in PP molecules. The isothermal crystallization kinetics of the blends was described with the Avrami equation. Values of the Avrami exponent indicated that crystallization nucleation of the blends is heterogeneous, the growth of spherulites is almost three-dimensional, and the crystallization mechanism of PP is not affected much by mLLDPE. The Avrami exponents of the blends are higher than that of pure PP, showing that the mLLDPE helps PP to form perfect spherulites. The crystallization rates of PP are decreased by mLLDPE because the crystallization temperature of PP was decreased by addition of mLLDPE and consequently the supercooling of the PP was correspondingly lower. The crystallization activation energy was estimated by the Friedman equation, and the result showed that the activation energy increased by a small degree by addition of mLLDPE, but changed little with increasing content of mLLDPE in the blends. The nucleation constant (K _g) was determined by the Hoffman–Lauritzen theory. Supported by the Science Foundation of Hebei University (2006Q13).     

Nonisothermal crystallization of metallocene propylene–decene‐1 copolymers

The nonisothermal crystallization behavior of one metallocene‐based isotactic polypropylene and three propylene–decene‐1 copolymers was studied. The effects of comonomer content and cooling rate were investigated. It was found that comonomer units enchained systematically reduce the crystallization temperature (T_c), melting temperature (T_m), fusion enthalpy (ΔH_f), and crystallinity (X_c). Such an effect becomes more evident at a faster cooling rate. With increasing comonomer content, the supercooling required for crystallization increases and the overall crystallization rate is reduced. The Avrami equation is applicable to describe the nonisothermal crystallization kinetics of propylene–decene‐1 copolymer. It was shown that, although the reduced crystallization rate constant Z_c increases with comonomer content, the Avrami exponent decreases with comonomer content and cooling rate, leading to the smaller overall crystallization rate and larger crystallization half‐time of the copolymer with higher comonomer content. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 1724–1730, 2004     

Synthesis and non‐isothermal crystallization behavior of poly(ethylene phthalate‐co‐terephthalate)s

A series of poly(ethylene phthalate‐co‐terephthalate)s were synthesized by melt polycondensation of ethylene glycol (EG) with dimethyl phthalate (DMP) and dimethyl terephthalate (DMT) in various proportions. The DMT‐rich polymers were obtained with reasonably high molecular weights, whereas the DMP‐rich polymers were synthesized with relatively low molecular weights due to steric effects associated with the highly kinked DMP monomer. The compositions and thermal properties of the polymers were determined. The copolymers containing DMP in amounts of ≤ 21 mol% were crystallizable, whereas the other polymers were not. All the polymers exhibited a single glass transition temperature. Analysis of the measured glass transition temperatures and crystal melting temperatures confirmed that the DMT‐rich copolymers are random copolymers. The non‐isothermal crystallization behaviors of the DMT‐rich copolymers were investigated by calorimetry and modified Avrami analysis. The Avrami exponents n were found to range from 2.7 to 3.8, suggesting that the copolymers crystallize via a heterogeneous nucleation and spherulitic growth mechanism; that is, the incorporation of DMP units as the minor component does not change the growth mechanism of the copolymers. In addition, the activation energies of the crystallizations of the copolymers were determined; the copolymers were found to have higher activation energies than the PET homopolymer. Polym. Eng. Sci. 44:1682–1691, 2004. © 2004 Society of Plastics Engineers.     

PE/PE‐g‐MAH/Org‐MMT nanocomposites. II. Nonisothermal crystallization kinetics

The nonisothermal crystallization kinetics of high‐density polyethylene (HDPE) and polyethylene (PE)/PE‐grafted maleic anhydride (PE‐g‐MAH)/organic‐montmorillonite (Org‐MMT) nanocomposite were investigated by differential scanning calorimetry (DSC) at various cooling rates. Avrami analysis modified by Jeziorny, Ozawa analysis, and a method developed by Liu well described the nonisothermal crystallization process of these samples. The difference in the exponent n, m, and a between HDPE and the nanocomposite indicated that nucleation mechanism and dimension of spherulite growth of the nanocomposite were different from that of HDPE to some extent. The values of half‐time (t_1/2), K(T), and F(T) showed that the crystallization rate increased with the increase of cooling rates for HDPE and composite, but the crystallization rate of composite was faster than that of HDPE at a given cooling rate. Moreover, the method proposed by Kissinger was used to evaluate the activation energy of the mentioned samples. It was 223.7 kJ/mol for composite, which was much smaller than that for HDPE (304.6 kJ/mol). Overall, the results indicated that the addition of Org‐MMT and PE‐g‐MAH could accelerate the overall nonisothermal crystallization process of PE. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 91: 3054–3059, 2004     

Melting,nonisothermal crystallization behavior and morphology of polypropylene/random ethylene—propylene copolymer blends

The melting, nonisothermal crystallization behavior and morphology of blends of polypropylene (PP) with random ethylene–propylene copolymer (PP‐R) were studied by differential scanning calorimetry, polarized optical microscopy, scanning electron microscopy, and X‐ray diffraction. The results showed that PP and PP‐R were very miscible and cocrystallizable. Modified Avrami analysis was used to analyze the nonisothermal crystallization kinetics of the blends. The values of the Avrami exponent indicated that the crystallization nucleation of the blends was heterogeneous, the growth of the spherulites was tridimensional, and the crystallization mechanism of PP was not affected by PP‐R. The crystallization activation energy was estimated using the Kissinger method. An interesting result was obtained with the modified Avrami analysis and the Kissinger method, whose conclusions were in good agreement. The addition of a minor PP‐R phase favored an increase in the overall crystallization rate of PP. Maximum enhancing effect wass found to occur with a PP‐R content of 20 wt %. The relationship between the composition and the morphology of the blends is discussed. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 99: 670–678, 2006     

Comparison of olefin copolymers as compatibilizers for polypropylene and high‐density polyethylene

Some polyolefin elastomers were compared as compatibilizers for blends of polypropylene (PP) with 30 wt % high‐density polyethylene (HDPE). The compatibilizers included a multiblock ethylene–octene copolymer (OBC), two statistical ethylene–octene copolymers (EO), two propylene–ethylene copolymers (P/E), and a styrenic block copolymer (SBC). Examination of the blend morphology by AFM showed that the compatibilizer was preferentially located at the interface between the PP matrix and the dispersed HDPE particles. The brittle‐to‐ductile (BD) transition was determined from the temperature dependence of the blend toughness, which was taken as the area under the stress–strain curve. All the compatibilized blends had lower BD temperature than PP. However, the blend compatibilized with OBC had the best combination of low BD temperature and high toughness. Examination of the deformed blends by scanning electron microscopy revealed that in the best blends, the compatibilizer provided sufficient interfacial adhesion so that the HDPE domains were able to yield and draw along with the PP matrix. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009