Structural and thermal stabilization of isotactic polypropylene/organo-montmorillonite/poly(ethylene-co-octene) nanocomposites by an elastomer component

Rheological and thermal properties of isotactic polypropylene (iPP)/organo-montmorillonite (OMMT)/poly(ethylene-co-octene) (PEOc) ternary nanocomposites and iPP/OMMT binary nanocomposites were studied by X-ray diffraction (XRD), rheometry, thermogravimetric analysis (TGA) and scanning electron microscopy (SEM) in this paper. The clay layers were mainly intercalated and partially exfoliated and well dispersed in these nanocomposites with the help of maleic anhydride modified polypropylene (PPgMA). Clay layers were mainly localized close to/inside the PEOc-rich phase from the direct observation of morphological study. A compact and stable network structure was formed in ternary composites when clay content was 2 phr (parts per hundred parts of iPP/PPgMA) or higher, which resulted in the lower stress relaxation rate and a pseudo-solid like behavior in low frequency region. Compared with iPP/OMMT composites, iPP/OMMT/PEOc composites had a much stronger ability to resist thermal decomposition. In another word, combining with the filler network, PEOc greatly improved the structural and thermal stabilities of iPP/OMMT nanocomposites.     

Preferential distribution of clay layers in iPP/OMMT/PEOc ternary nanocomposites

Isotactic polypropylene (iPP)/organo-montmorillonite (OMMT) nanocomposite was modified by poly(ethylene-co-octene) (PEOc). PEOc-rich domains were well dispersed in the iPP matrix, with narrowly distributed size. OMMT layers were well dispersed, mainly intercalated and partially exfoliated. Compared with the case in the binary composites, many OMMT layers were preferential distributed inside and around the PEOc-rich domains in the ternary composite samples, which formed an enhanced OMMT filler network. The reason for the OMMT preferential distribution was considered to be dragged or wrapped by PEOc-rich domains during sample preparation and phase separation.     

Shear-induced orientation in the crystallization of an isotactic polypropylene nanocomposite

Isothermal crystallization of isotactic polypropylene (iPP)/organic montmorillonite (OMMT) binary composite under shear field was investigated by in situ polarized optical microscopy, rheometry and transmission electron microscopy. When shear strain was small, shear flow could enhance the crystallization of iPP, and the crystallizing entity was spherulitic in iPP/OMMT composite in which the OMMT content was below the percolation threshold. With shear strain increasing, the orientation extent became stronger and cylindrites and strings of spherulites appeared in these samples. However, for iPP/OMMT composite with OMMT content higher than the percolation threshold, when the shear strain was not big enough to destroy the fillers network in the matrix, the crystallization of iPP was similar with that of the un-sheared sample. When shear strain was large enough, the fillers network was destroyed and clay layers were aligned along the flow direction. There formed oriented crystals including cylindrites and strings of spherulites, which were much smaller in size than those formed in the previous case, because the aligned clay layers acted as heterogeneous nucleation agents to promote crystallization of iPP.     

Mechanisms of nucleation and crystal growth in a nascent isotactic polypropylene/poly (ethylene-co-octene) in-reactor alloy investigated by temperature-resolved synchrotron SAXS and DSC methods

The nucleation and lamellar growth mechanisms of nascent isotactic polypropylene/poly(ethylene-co-octene) (N-iPP/PEOc) in-reactor alloy were investigated with temperature-resolved synchrotron small angle X-ray scattering (SAXS), differential scanning calorimeter (DSC) and polarized optical microscopy (POM) methods. We have observed two crystallization peaks (fractionated crystallization behavior) during cooling process in N-iPP/PEOc in-reactor alloy. We also determined that the crystallinities from that two crystallization peaks were dependent on liquid-liquid phase separation (LLPS) time with t^0.10 and t^−0.28, respectively. It was explained that the fractionated crystallization behavior in the N-iPP/PEOc in-reactor alloy system was caused by crystal nucleation occurring in the iPP rich domain by heterogeneous nucleation and at interface of iPP and PEOc rich domains by the fluctuation assisted nucleation. The fluctuation assisted nucleation only occurred at interface of iPP and PEOc domains by concentration fluctuation through the coupling of liquid-liquid spinodal decomposition and the cross-over to crystal nucleation process. Both lamellar crystals formations from heterogeneous and fluctuation assisted nucleation in N-iPP/PEOc were probed by temperature-resolved SAXS during cooling process. Our results provide the physical model for the multiple nucleation and crystal growth mechanisms in the multi-component, multi-phase polymer systems such as in-reactor alloy or blend.     

Effects of liquid–liquid phase separation on crystallization kinetics and morphology of isotactic polypropylene/poly (ethylene-co-octene) in-reactor alloy

In this work, we investigated the effects of liquid–liquid phase separation (LLPS) on the crystallization kinetics and morphology of isotactic polypropylene/poly (ethylene-co-octene) (iPP/PEOc) in-reactor alloy with polarized optical microscopy (POM), differential scanning calorimeter (DSC), scanning electron microscopy (SEM), wide angle X-ray scattering (WAXS) and small angle X-ray scattering (SAXS) methods. Based on crystallization kinetics analysis by Avrami equation, we found that the overall crystallization rate was almost independent on LLPS time, whereas was strongly dependent on crystallization temperature. However, by combination with POM, we found that the LLPS played two opposite roles on the overall crystallization rate, i.e. the nucleation rate decreased and the spherulite growth rate increased as increasing LLPS time. It is due to the nucleation rate was dominated by fluctuation-assisted nucleation mechanism and the growth rate was dominated by diffusion-controlled growth. Furthermore, the spherulite size and PEOc domain size of iPP/PEOc in-reactor alloy were significantly dependent on LLPS time; however, the crystallinity was almost not dependent on LLPS time.     

Stereochemical composition-properties relationships in isotactic polypropylenes obtained with different catalyst systems

The influence of stereochemical composition of the radial growth rate of spherulites, the nucleation density, the overall rate of crystallization and the thermal behaviour of fractions of iPP samples synthesized with different catalyst systems (low, high and very high yield) was investigated. The study used ¹³C n.m.r., differential scanning calorimetry (d.s.c.) and optical microscopy. The ¹³C n.m.r. analysis showed that due to the presence of catalytic sites with different stereoregulating capability the catalyst system produces polypropylene with different stereoregularity. It was found that the growth rate of spherulites and the overall rate of crystallization are strictly related to the stereochemical structure of the polypropylene. Moreover, for the low yield iPP, phenomena of secondary crystallization were observed by Avrami analysis of the overall kinetics. Values of the equilibrium melting temperature (T_m), energy of nucleation (Δø1) and surface free energy of folding (σe) of iPP lamellar crystals have been determined according to the kinetic theory of polymer crystallization. The values of such thermodynamic quantities as well as the thermal behaviour of various iPP are strongly dependent upon the amount and distribution of configurational irregularities existing along the chains and upon the molecular mass distribution.     

Morphology of a melt crystallized iPP/HDPE/hydrogenated hydrocarbon resin blend

The structure, phase structure, morphology, crystallization and melting behavior of isotactic polypropylene (iPP) blended with a master batch (MB), formed by high density polyethylene and hydrogenated hydrocarbon resin (iPP/MB), have been in details investigated by using X-ray diffraction, optical microscopy and differential scanning calorimetry. It was found that the structure and morphology depend on crystallization conditions. A new family of α spherulites of iPP (type I spherulites) can be activated using appropriate crystallization conditions. Nucleation of these spherulites has been explained by using the approach of nucleus migration in polymer blends. Type I spherulites present specific morphological, kinetic and thermal behaviors. In particular it was found that the growth rate of type I spherulites, at a given T_c, is higher than the growth rate of spherulites grown from plain iPP.     

Interplay between crystallization behaviors and extensional deformation of isotactic polypropylene and its blend with poly(ethylene-co-octene)

Comparison investigation of the interaction between crystallization behaviors and extensional deformation of both isotactic polypropylene (iPP) and its blend with poly(ethylene-co-octene) (iPP/PEOc) was carried out in this study. The samples of iPP and the iPP/PEOc (80/20, wt.%) blend were prepared by changing the cooling rate during nonisothermal crystallization. Tensile testing showed that with the decrease of cooling rate, the progressive destruction of ductility of the two samples was resulted from the more perfect crystallites formed in the cooling process. The influence of cooling rate on the tensile properties is more prominent for pure iPP than for the iPP/PEOc blend. The crystalline structure was proven to be partially destroyed under the extensional deformation, and such crystalline structure destruction was in close association with the deformation of the specimens. The oriented noncrystalline molecular chains could easily be reorganized into more perfect crystals in postheating runs. The original crystalline structure has been found, to some extent, to determine the extensional deformation and the final crystallization behavior.     

Isothermal crystallization kinetics and morphology development of isotactic polypropylene blends with atactic polypropylene

The crystallization kinetics and morphology development of pure isotactic polypropylene (iPP) homopolymer and iPP blended with atactic polypropylene (aPP) at different aPP contents and the isothermal crystallization temperatures were studied with differential scanning calorimetry, wide‐angle X‐ray diffraction, and polarized optical microscopy. The spherulitic morphologies of pure iPP and larger amounts of aPP for iPP blends showed the negative spherulite, whereas that of smaller amounts of aPP for the iPP blends showed a combination of positive and negative spherulites. This indicated that the morphology transition of the spherulite may have been due to changes the crystal forms of iPP in the iPP blends during crystallization. Therefore, with smaller amounts of aPP, the spherulitic density and overall crystallinity of the iPP blends increased with increasing aPP and presented a lower degree of perfection of the γ form coexisting with the α form of iPP during crystallization. However, with larger amounts of aPP, the spherulitic density and overall crystallinity of the iPP blends decreased and reduced the γ‐form crystals with increasing aPP. These results indicate that the aPP molecules hindered the nucleation rate and promoted the molecular motion and growth rate of iPP with smaller amounts of aPP and hindered both the nucleation rate and growth rate of iPP with larger amounts of aPP during isothermal crystallization. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 1093–1104, 2007     

Spherulite nucleation in blends of isotactic polypropylene with isotactic poly(butene-1)

The phase morphology and the influence of composition on the primary nucleation of isotactic polypropylene in isotactic polypropylene/isotactic poly(butene-1) (iPP/iPB) blends were investigated by electron and light microscopy and small-angle light scattering. It was found that iPP and iPB are miscible but the thermal treatment induces partial phase separation of components and the formation of iPP-rich and iPB-rich phases. The complete phase separation needs high temperatures and/or a long time of melt annealing. In samples crystallized isothermally at low undercooling the heterogeneous primary nucleation in blends is depressed as compared to plain iPP. In blends the less active heterogeneities lose their activity because of an increase of the energy barrier for critical size nucleus formation due to phase separation of blend components during crystallization. For the same reason the rate of homogeneous nucleation in blends decreases, as observed in samples crystallized at very high undercooling. At very high undercooling iPP and iPB are able to crystallize with similar rates, which results in the formation of a fraction of iPB spherulites in addition to iPP spherulites. Consequently the number of spherulites in the blend is larger than that in plain iPP, in spite of the decrease in the homogeneous nucleation rate of iPP in the blend. © 1994 John Wiley & Sons, Inc.     

Temperature dependence of the nucleation effect of sorbitol derivatives on polypropylene crystallization

The temperature dependence of the nucleation effect of three sorbitol derivatives on the crystallization of isotactic polypropylene (iPP) was studied by means of isothermal crystallization kinetic analysis. Isothermal crystallization thermograms obtained by differential scanning calorimetry (DSC) were analyzed based on the Avrami equation. The Avrami analysis for the nucleated iPP was carried out with DSC data collected to 35% relative crystallinity, and the rate constants were corrected assuming the heterogeneous nucleation and three dimensional growth of iPP spherulites. A semi-empirical equation for the radial growth rate of iPP spherulites was given as a function of temperature and was used to determine the number of effective nuclei at different temperatures. The number of effective nuclei in the nucleated samples was estimated to be 3 × 10² ∽ 10⁵ times larger than that in the neat iPP. The logarithmic numbers of the effective nuclei decreased linearly with decreasing degree of supercooling in the range of crystallization temperatures tested. The temperature dependence of the effect of the nucleating agents on iPP crystallization was given quantitatively in terms of the deactivation factor defined as a fraction of the particles that are active at a particular temperature but inert at the temperature one degree higher. The nucleation activity and its temperature dependence are considered to be cooperative effects of many factors, including the dispersion and the physical or chemical nature of the agent as well as the interaction between the agent and the polymer. It is suggested that the temperature dependence of the effect of a nucleating agent should be treated as a characteristic of a given polymer/ nucleating agent mixture.     

Ductile-brittle transition controlled by isothermal crystallization of isotactic polypropylene and its blend with poly(ethylene-co-octene)

The correlation between crystalline morphology development and tensile properties of isotactic polypropylene (iPP) and its blend with poly(ethylene-co-octene) (PEOc) was investigated to study the ductile-brittle transition (DBT) in fracture modes. The sample processing strategy and the scientific observations have never been reported previously. The samples were first isothermally crystallized at 130 °C, 123 °C or 115 °C for a wide range of crystallization times, and then quenched to 35 °C for characterization. It was found that the crystallization conditions including crystallization temperature and time governed the crystalline morphology and even the tensile properties of iPP and the iPP/PEOc (80/20) blend. The lower the crystallization temperature, the shorter the crystallization time was needed for the occurrence of DBT, and the sharper the transition would be. The addition of the elastomer component delayed the DBT occurrence for the iPP/PEOc blend in terms of the crystallization time, owing to the fact that the existence of PEOc domains between the iPP lamellar stack regions or at the iPP spherulitic boundaries enhanced the ductility of the blend. The X-ray diffraction results displayed the oriented and destroyed crystalline structure characterizing the ductile fracture, while unoriented structure describing the brittle failure. The DBT is closely related to the crystal perfection, and factors such as the crystallization temperature and time and the compositions have been proven to be significant variables in determining the DBT occurrence.     

Effects of EPDM and wollastonite on structure of isotactic polypropylene blends and composites

Polypropylene blends and composites with 5, 10, and 15 vol % of EPDM and 2, 4, and 6 vol % of untreated and treated wollastonite filler were examined by applying different techniques. Elastomeric ethylene/propylene/diene terpolymer (EPDM) component and wollastonite influenced the crystallization process of isotactic polypropylene (iPP) matrix in different ways. The nucleation of hexagonal β‐iPP, the increase of overall degree of crystallinity, and crystallite size of iPP were more strongly affected by wollastonite than the addition of EPDM was. Both ingredients also differently influenced the orientation of α‐form crystals in iPP matrix. Wollastonite increased the number of a*‐axis‐oriented α‐iPP lamellae plan parallel to the sample surface, whereas the addition of EPDM reoriented the lamellae. The orientation parameters of ternary composites exhibited intermediate values between those for binary systems because of the effects of both components. EPDM elastomer considerably affected well‐developed spherulitization of iPP, increasing the spherulite size. Contrary to EPDM, because of nucleating ability or crystal habit, wollastonite caused significantly smaller iPP spherulites. Small spherulites in ternary iPP/EPDM/wollastonite composites indicated that the wollastonite filler (even in smallest amounts) exclusively determined the morphology of ternary composites. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 91: 4072–4081, 2004     

Morphology,crystallization and melting behaviour of films of isotactic polypropylene blended with ethylene-propylene copolymers and polyisobutylene

The crystallization, the morphology and the thermal behaviour of thin films of isotactic polypropylene (iPP) blended with elastomers such as random ethylene-propylene copolymers (EPM) with different ethylene content and polyisobutylene (PiB) were investigated by means of optical microscopy, differential scanning calorimetry and wide angle X-ray diffractometry. During crystallization EPM copolymers are ejected on the surface of the film forming droplet-like domains. A different morphology is observed in iPP/PiB blends. For these mixtures the elastomers separate from the iPP phase forming spherical domains that are incorporated in the iPP intraspherulitic regions. Both EPM and PiB elastomers act as nucleant agents for iPP spherulites. This nucleation efficiency is strongly dependent on the chemical structure and molecular mass of the elastomers. The addition of EPM causes an elevation of the observed and equilibrium melting temperature of iPP. This unusual effect may be accounted for by assuming that the elastomers are able to extract selectively the more defective molecules of iPP. The depression of the growth rate of spherulites and the observed and equilibrium melting temperature of iPP, noted in iPP/PiB blends, suggests that these two polymers have a certain degree of compatibility in the melt.     

Time evolution of phase structure and corresponding mechanical properties of iPP/PEOc blends in the late-stage phase separation and crystallization

A typical toughened polymeric alloy system, isotactic polypropylene (iPP)/poly(ethylene-co-octene) (PEOc) blend, was selected in this study to investigate the influence of phase separation and crystallization on the final mechanical properties of the polyolefin blend. The time dependence of the morphology evolution of this iPP/PEOc blend with different compositions was annealed at both 200 and 170 °C and investigated with scanning electron microscopy (SEM) and phase contrast optical microscopy (PCOM). It was found that under the above two phase separation temperatures, the domain size of iPP80/PEOc-20 (PEOc-20) increases only slightly, while the structure evolution of iPP60/PEOc-40 (PEOc-40) is quite prominent. The tensile tests revealed that the mechanical properties of PEOc-20, including break strength and elongation at break decrease only in a very small amount, while those of PEOc-40 are depressed obviously with phase separation time. The decrease of interphase and a sharper boundary resulting from domain coarsening during the late-stage phase separation are responsible for the poor tensile properties. It is believed that the composition, the annealing time and the processing temperatures all contribute to the morphology evolution and the consequent mechanical properties of iPP/PEOc blends, furthermore, the crystallization procedure is another crucial factor influencing the ultimate mechanical properties of the investigated blends.     

The influence of rubber-matrix interfaces on the crystallization kinetics of isotactic polypropylene blended with ethylene-propylene-diene terpolymer (EPDM)

Blends of isotactic polypropylene with amorphous and slightly crystalline ethylene-propylene-diene terpolymer (EPDM), prepared by solution blending, have been investigated by optical microscopy and differential scanning calorimetry. Nucleation and crystallization kinetic parameters, such as nucleation rates, nucleation half times, Avrami-exponents and spherulitic growth rates, have been determined. It has been found that the dispersion of crystalline EPDM in iPP is different from that of amorphous EPDM. Both EPDMs are incorporated into the spherulites, causing a decrease of the maximum growth rate of the iPP spherulites. The surface free energy of the iPP crystals is diminished on adding EPDM to iPP and is accompanied by a higher secondary nucleation rate. From the decrease observed in the Avrami exponent with increasing EPDM concentration in the blend, it has been concluded that nucleation becomes predominantly heterogeneous, as there is a proportional increase in the interfacial area between the two components.     

Nucleation effect of inclusion complexes with different polyolefin as guest molecules on the crystallization of polypropylene

The γ‐cyclodextrin (γ‐CD) inclusion complexes (ICs) with four kinds of polyolefin (PO) as guest molecules were prepared. The crystallization behavior of isotactic polypropylene (iPP) blended with the γ‐CD and γ‐CD–PO ICs was investigated by differential scanning calorimetry, polarized optical microscopy, and light scattering. The iPP blended with the ICs was found to exhibit higher crystallization temperature (T_C), smaller spherulites, and faster crystallization rate than those of neat iPP, indicating that the ICs play a role of nucleating agent on the crystallization of iPP and induce accelerated crystallization. The IC with PO having higher T_C as guest molecules showed higher nucleation effect than the IC with PO having lower T_C as guest molecules. The results suggest that the nucleation effect of these ICs was affected by the kinds of the guest molecules. The higher T_C guest molecules could result in higher nucleation effect. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Modeling of flow‐induced crystallization in blends of isotactic polypropylene and poly(ethylene‐co‐octene)

Poly(ethylene‐co‐octene) (PEOc) has been shown to provide a high toughening contribution to isotactic polypropylene (iPP). The theoretical modeling of flow‐induced crystallization (FIC) of blends of iPP and PEOc is not much reported in the literature. The aim of the present work is to clarify the FIC of iPP upon addition of PEOc in terms of theoretical modeling. The crystallization of iPP and PEOc blends in flow is simulated by a modified FIC model based on the conformation tensor theory. Two kinds of flow fields, shear flow and elongational flow, are considered in the prediction to analyze the influence of flow field on the crystallization kinetics of the polymer. The simulation results show that the elongation flow is much more effective than shear flow in reducing the dimensionless induction time of polymer crystallization. In addition, the induction time of crystallization in the blends is sensitive to the change of shear rate. In comparison with experimental data, the modified model shows its validity for the prediction of the induction time of crystallization of iPP in the blends. Moreover, the simulated relaxation time for the blends becomes longer with increasing percentage of PEOc in the blends. Copyright © 2012 Society of Chemical Industry     

Enhanced spherulite growth rates of isotactic polypropylene in incompatible blends

Isothermal radial growth rates (G) of isotactic polypropylene (iPP) spherulites in immiscible blends with a polyethylene based ionomer (1) partially neutralized with Zn⁺², (2) completely acidified, and (3) completely esterified have been determined at crystallization temperatures between 118 and 124°C by time-lapse photomicroscopy. In these blends iPP spherulites grow with increased G as compared to that of pure iPP. This behavior is attributed to increases in the rate of transport, due to limited miscibility induced by mechanical mixing. However, subtle differences in the melting behavior suggest that changes in Spherulite morphology may also be a contributing factor.     

Role of multi-wall carbon nanotube network in composites to crystallization of isotactic polypropylene matrix

The composites (iPP/CNTs) made of isotactic polypropylene (iPP) and multi-wall carbon nanotubes (CNTs) were prepared by solution blending. To improve compatibility between CNTs and iPP and to enhance dispersion of CNTs in iPP matrix, CNTs were chemically modified by grafting alkyl chains. The chemically modified CNTs had about 6 wt% grafted alkyl chains. Rheological measurements indicated that CNTs caused gelation in iPP/CNTs due to CNT network formation and the critical gelation CNT concentration was about 7.4 wt%, which was considered to be high due to the low CNT aspect ratio in this study. Crystallization behaviors of iPP/CNTs were studied by using optical microscopy (OM) and differential scanning calorimetry (DSC). Radial growth rates of spherulites during isothermal crystallization of iPP/CNTs with CNT concentrations less than 2.0 wt% measured by using OM showed decreasing trends with increasing CNT concentration. Avrami analysis of the exothermic heat flow curves during isothermal crystallization of iPP/CNTs measured by DSC indicated that crystallization rates were accelerated when CNT concentrations were lower than the critical gelation concentration, because CNTs mainly functioned as nucleating agents for crystallization, while crystallization rates did not change obviously when CNT concentrations were higher than the critical gelation concentration, because CNT network could form and mainly functioned to provide restriction to mobility and diffusion of iPP chains to crystal growth fronts.