The relationship between mechanical properties and morphology of vibration‐injection‐molded polyethylene

This paper introduces a novel melt vibration‐injection molding. The effect of mid‐frequency melt vibration on mechanical properties was introduced, and SEM, WAXD and DSC investigations had been employed to provide evidence for explaining the relationship between mechanical properties and morphology of vibration‐injection‐molded specimens. The results show that the effect of vibration frequency is very different from that of vibration pressure amplitude. At a given vibration pressure amplitude, the increase of vibration frequency is beneficial for obtaining preferential orientation, more perfect lamellae and enhanced mechanical properties. For a given vibration frequency, increase of vibration pressure amplitude is a pre‐requisite for the achievement of a large‐scale lamella, more pronounced orientation, increase of cyrstallinity and high strength of high‐density polyethylene, but part of the toughness is lost. Copyright © 2004 Society of Chemical Industry     

Effect of chitin addition on injection‐molded thermoplastic corn starch

A new type of biodegradable starch‐based composites was prepared by injection‐molding using glycerol and water as plasticizers. Chitin flakes, obtained from shells of Penaeusschmitti, were used as reinforcing phase. The effect of chitin content on the structural and tensile properties of the composite samples was examined after conditioning at 28°C and 80% relative humidity for 30 days. In general, chitin incorporation into the starch matrix resulted in materials with higher modulus and decreased elongation at break. Wide‐angle X‐ray diffraction and differential scanning calorimetry evidenced a significant decrease in crystallinity in the composite samples in relation to the unfilled starch material. Contact angle measurements revealed that the addition of chitin contributes to the improvement of water resistance of the composite samples when compared to injection molded starch alone. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 92: 2706–2713, 2004     

Optical properties of injection‐molded polystyrene scintillators. I. Processing and optical properties

Scintillating tiles for the Tilecal/Atlas calorimeter can be produced by injection molding, an alternative to mold casting via in situ polymerization. This new production method, which leads to a much faster production rate, introduces a number of additional variables that affect the optical yield of the scintillators and that have not yet been reported in the literature. In this work, the effect of processing‐induced orientation on the optical properties of the scintillators is analyzed and discussed. For this purpose, the birefringence across the thickness of the scintillator has been measured. The variations of the birefringence may be correlated with the orientation and, therefore, related to the optical performance, that is, the average light output and its nonuniformity. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 2706–2713, 2003     

The cell forming process of microcellular injection‐molded parts

In this article, we studied the cell forming process of microcellular injection‐molded parts. Using a modified injection molding machine equipped with a Mucell^® SCF delivery system, microcellular‐foamed acrylonitrile–butadiene–styrene parts with different shot sizes were molded. The cell structure on the fractured surfaces along the direction both vertical and parallel to melt flow in the molded parts was examined. The results showed that a regular spherical cells region and a distorted ellipsoidal cells region exist in the molded parts simultaneously. The length of the distorted cells region along the melt flow direction in the molded parts remained basically unchanged for different shot sizes and it is about 195 mm away from the flow front in this study's conditions. The cell formation mechanism was analyzed, two cell forming processes in microcellular injection molding, the “foam during filling” process and the “foam after filling” process, were proposed. It was also found that the melt pressure in the filling stage is the dominant factor affecting the cell forming process, and there is a critical melt pressure value in the filling stage, 20.9 MPa, as the dividing line of the two cell forming processes in this study. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40365.     

Effect of melt flow on morphology and linear thermal expansion of injection‐molded ethylene–propylene–diene terpolymer/isotactic polypropylene blends

An ethylene–propylene–diene terpolymer/isotactic polypropylene blend with a structure of co‐continuous microlayers was fabricated by injection molding and was then investigated. The blend exhibited an extremely low coefficient of linear thermal expansion (CLTE) in the directions of the length and the width. As the thickness of the oriented portion increased, the CLTE was further reduced. The morphology of the co‐continuous microlayers and the thermal expansion behavior varied with the sampling positions on the injection‐molded sheets. To study the relationship between the morphology and the melt flow, the melt flow behavior during injection molding was simulated using Moldflow. Orientation of the microlayers was determined using shear flow. When the shear rate increased, the orientation state increased and the CLTE decreased. © 2015 Society of Chemical Industry     

Characterization of molecular orientation in injection–stretch–blow‐molded poly(ethylene terephthalate) bottles by means of external reflection infrared spectroscopy

The molecular orientation at the outer surface of injection–stretch–blow‐molded bottles made from poly(ethylene terephthalate) was characterized and quantified by means of front‐surface reflection infrared spectroscopy based on a method developed previously. Results were obtained for two different bottle shapes (cylindrical and rectangular) molded at different injection mold temperatures (16, 38, and 60°C). For the cylindrical bottles, the preferred molecular chain orientation was found to be in the axial direction, with the Hermans orientation function near 0.3 for all three mold temperatures. For the less symmetrical rectangular bottles, a significant difference was observed between the large and small faces. For the large face, the orientation was mainly in the hoop direction; the Hermans orientation function was in the range of 0.3–0.5 and was essentially the same at all mold temperatures and positions along the bottle height. For the small face, on the other hand, the preferred orientation changed from the hoop direction near the bottom to the axial direction near the top, and the variation was more pronounced at lower mold temperatures. The utility of the front‐surface reflection technique was clearly demonstrated. It was also applied, with the use of an infrared microscope, to examine the orientation gradient across the wall thickness. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 1319–1327, 2007     

Morphology and mechanical properties of injection‐molded ultrahigh molecular weight polyethylene/polypropylene blends and comparison with compression molding

The mechanical properties and morphology of UHMWPE/PP(80/20) blend molded by injection and compression‐molding were investigated comparatively. The results showed that the injection‐molded part had obviously higher Young's modulus and yield strength, and much lower elongation at break and impact strength, than compression‐molded one. A skin‐core structure was formed during injection molding in which UHMWPE particles elongated highly in the skin and the orientation was much weakened in the core. In the compression‐molded part, the phase morphology was isotropic from the skin to the core section. The difference in consolidation degree between two molded parts that the compression molded part consolidated better than the injection one was also clearly shown. In addition, compositional analysis revealed that there was more PP in the skin than core for the injection‐molded part, whereas opposite case occurred to the compression‐molded one. All these factors together accounted for the different behavior in mechanical properties for two molded parts. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Melting and crystallization behaviors of injection‐molded polypropylene

The melting and crystallization behaviors of the skin layer in an injection‐molded isotactic polypropylene (PP) have been studied, mainly in comparison with those of the core layer and subsidiarily in comparison with those of a compression‐molded PP and a nucleator (talc)–added PP. The skin layer contains about 5% crystals, which have a high melting point of up to 184°C. They thermally vanish by melting once. The subsequent melting history will scarcely affect the melting behaviors. On the other hand, crystallization behaviors are strongly affected by the melting history. The skin layer crystallizes in a wide temperature range at high temperature. This tendency weakens with increasing melting temperature, approaching a constant and that of the core layer above 230°C, which suggests that the memory effect of the residual structure of PP vanishes by melting above 230°C. In explaining these experimental results, it is assumed that the residual structure substance is a melt orientation of molecular chains that works as crystallization nuclei and that the vanishing of the residual structure is nothing but a relaxation of the melt orientation. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 78: 1751–1762, 2000     

Influence of fiber orientation and fiber content on properties of sisal‐jute‐glass fiber‐reinforced polyester composites

The incorporation of natural fibers with polymer matrix composites (PMCs) has increasing applications in many fields of engineering due to the growing concerns regarding the environmental impact and energy crisis. The objective of this work is to examine the effect of fiber orientation and fiber content on properties of sisal‐jute‐glass fiber‐reinforced polyester composites. In this experimental study, sisal‐jute‐glass fiber‐reinforced polyester composites are prepared with fiber orientations of 0° and 90° and fiber volume of sisal‐jute‐glass fibers are in the ratio of 40:0:60, 0:40:60, and 20:20:60 respectively, and the experiments were conducted. The results indicated that the hybrid composites had shown better performance and the fiber orientation and fiber content play major role in strength and water absorption properties. The morphological properties, internal structure, cracks, and fiber pull out of the fractured specimen during testing are also investigated by using scanning electron microscopy (SEM) analysis. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 42968.     

An X‐ray scattering study of water‐conditioned injection‐molded starch during isothermal heating

The in situ structure variation of injection‐molded starch (as processed and after water conditioning) during heat treatment was investigated by means of wide‐angle X‐ray scattering using synchrotron radiation. Results confirm that the crystal structure of potato starch is destroyed after injection molding, while as‐processed corn starch preserves some degree of crystallinity. This residual crystallinity in corn starch is related to the crystalline Vh‐form, made of complexes of amylose with lipids. Furthermore, it is shown that both starch types can develop crystallinity by water conditioning: potato starch yields the crystal B‐form, while corn starch yields the crystal A‐form coexisting with the persistent Vh‐form. Upon isothermal heating of samples under vacuum, a rapid decrease of crystallinity, which is a function of both time and treatment temperature, is detected. Crystallinity variations are discussed in terms of water evaporation, the leveling‐off values of crystallinity being dependent on the temperature of the isothermal treatment. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 17–21, 2003     

Synthesis and characterization of biodegradable low molecular weight aliphatic polyesters and their use in protein‐delivery systems

Poly(lactic acid) (PLA) and poly(lactic‐co‐GA) (PLGA) with low molecular weights were synthesized by a one‐step polycondensation of lactic acid (LA) with glycolic acid (GA) molecules using stannous octoate as a catalyst at 160°C. A high yield (>80%) of all the polymers was obtained in the study. The PLA and PLGA copolymers were characterized by ¹H‐NMR, GPC, and DSC measurements, etc. We elaborated HSA‐loaded microspheres based on PLA and PLGA copolymers with different monomer ratios (LA/GA = 85:15, 75:25, 65:35, and 50:50) by the solvent‐extraction method based on the formation of double w/o/w emulsion. Microspheres were characterized in terms of the morphology, size, and encapsulation efficiency (E.E.). The highest E.E. (69.3%) of HSA was obtained for HSA‐loaded PLGA (65/35) microspheres among all the formulations. In vitro matrix degradation and protein release of these microspheres were performed in phosphate‐buffer saline (PBS; 154 mM, pH 7.4). The degradation profiles were characterized by measuring the loss of the microsphere mass and the decrease of the polymer intrinsic viscosity. The release profiles were investigated from the measurement of the protein presented in the release medium at various intervals. It was shown that the matrix degradation and protein‐release profiles were highly LA/GA ratio‐dependent. It is suggested that these matrix polymers may be optimized as carriers in protein‐ and peptide‐delivery systems for different purposes. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 91: 1848–1856, 2004     

Lipase‐catalyzed synthesis and characterization of biodegradable polyester containing l‐malic acid unit in solvent system

Lipase‐catalyzed direct polycondensation of L ‐malic acid (L ‐MA), adipic acid, and 1,8‐octanediol in organic media was achieved using Novozym 435 as the biocatalyst. ¹H‐nuclear magnetic resonance spectroscopy indicated that the selectivity of Novozym 435 was unaffected by changes in the organic media. The molecular weight (M_w) of the copolymers was affected by the L ‐MA feed ratio in the diacids, hydrophobicity of the solvent, and solubility of the substrates in the solvents. The M_w reached a maximum of 17.4 kDa at 80°C in isooctane at a L ‐MA feed ratio in the diacids of 40 mol %. The M_w increased from 3.2 to 16.6 kDa when the reaction time was extended from 6 to 48 hr at 70°C, and remained relatively constant with further increases in reaction time from 48 to 72 hr. The hydrophilicity, thermal stability, and crystallizability of the copolymer were also investigated. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Effect of process conditions on the dart impact properties of thin‐wall injection‐molded polycarbonate plates

Multifunctional mobile products, such as cellular phones, laptop computers, personal media players, etc., have become smaller and lighter; so the technology of thin‐wall injection molding (TWIM) has been highlighted for making lightweight and compact mobile electronic products. Regarding mechanical properties, many portable electronic products should pass the so‐called “drop test”; therefore, the evaluation of the dart (or impact) property of the housing that is made by the TWIM process is crucial for commercializing a product. However, extant research on the effect of injection molding process parameters on the physical properties of TWIM plates is insufficient as yet. Therefore, in this study, the pressure and temperature inside the cavity during the injection molding process are monitored by varying the injection molding process parameters, i.e., the gate size, injection speed, and melt temperature, and the effect of the average flow rate of the molten resin inside the cavity on the dart property of thin‐wall injection‐molded plates is examined. The dart property of thin‐wall injection‐molded plates is evaluated by the instrumented dart impact test to differentiate various responses of the load‐displacement data during dart tests. © 2012 Wiley Periodicals, Inc. J Appl Polym Sci., 2013     

Structure and properties of injection‐molded polypropylenes with different molecular weight distribution and tacticity characteristics

Two series of polypropylenes with different molecular weight distribution and tacticity characteristics were injection molded into flexural test specimens by varying cylinder temperature and the effects of the molecular weight distribution and tacticity on the structure and properties of the moldings were studied. Measured propertied were flexural modulus, flexural strength, heat distortion temperature, Izod impact strength, and mold shrinkage and structures studied were crystallinity, the thickness of skin layer, a*‐axis‐oriented component fraction and crystalline orientation functions. The relations between the structures and properties were also studied. It was found that the molecular weight distribution and tacticity characteristics affect the properties mainly through the molecular orientation and crystallinity, respectively. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 2142–2156, 2002     

Mechanical and chemical stability of injection‐molded microcantilevers used for sensing

Ultraviolet‐ozone treatment is used as a standard surface cleaning procedure for removal of molecular organic contamination from analytical and sensing devices. Here, it is applied for injection‐molded polymer microcantilevers before characterization and sensing experiments. This article examines the effects of the surface cleaning process using commercial equipment, in particular on the performance and mechanical properties of the cantilevers. It can be shown that the first chemical aging process essentially consist of the cross linking of the polymer chains together with a physical aging of the material. For longer exposure, the expected thermo‐oxidative formation of carbonyl groups sets in and an exposure dependent chemical degradation can be detected. A process time of 20 min was found suitable as a trade‐off between cleaning and stability. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Study on thermal expansion in injection‐molded isotactic polypropylene and thermoplastic elastomer blends

The linear thermal expansion coefficients (CLTEs) along flow direction (FD) for the injection‐molded blends composed of isotactic polypropylene (iPP) and various ethylenic thermoplastic elastomers (TPEs) were investigated using a thermo‐mechanical analyzer. The iPP/TPE blends with higher comonomer contents in the TPE showed extremely low CLTE. TEM observation revealed that the array of the TPE whose MFR was adjusted to be higher than the iPP matrix was in lamella‐like sheet stacked normal to normal direction (ND) with being elongated along both FD and transverse‐to‐flow direction. At higher magnification of TEM, the iPP lamellae in the blend with higher comonomer contents in the TPE deeply penetrated into the TPE phase as a consequence of the faster iPP crystallization before the completion of the phase‐separation. Hence, the location of the iPP amorphous chains would change depending on the comonomer contents in the TPE; in the case of the iPP/TPE blend with higher comonomer contents, large amount of the iPP amorphous chains would be trapped inside the TPE phase because of incomplete phase‐separation arrested by faster crystallization. Therefore, the extremely low CLTE for the iPP/TPE blend with higher comonomer contents was accounted for by the simultaneous suppression of the thermal expansions from both the TPE phase and the iPP amorphous chains trapped inside the TPE by rigid iPP crystalline lamellae connecting in parallel with the TPE phase. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

In situ composites from blends of polycarbonate and a thermotropic liquid‐crystalline polymer: The influence of the processing temperature on the rheology,morphology, and mechanical properties of injection‐molded microcomposites

This work was aimed at understanding how the injection‐molding temperature affected the final mechanical properties of in situ composite materials based on polycarbonate (PC) reinforced with a liquid‐crystalline polymer (LCP). To that end, the LCP was a copolyester, called Vectra A950 (VA), made of 73 mol % 4‐hydroxybenzoic acid and 27 mol % 6‐hydroxy‐2 naphthoic acid. The injection‐molded PC/VA composites were produced with loadings of 5, 10, and 20 wt % VA at three different processing barrel temperatures (280, 290, and 300°C). When the composite was processed at barrel temperatures of 280 and 290°C, VA provided reinforcement to PC. The resulting injection‐molded structure had a distinct skin–core morphology with unoriented VA in the core. At these barrel temperatures, the viscosity of VA was lower than that of PC. However, when they were processed at 300°C, the VA domains were dispersed mainly in spherical droplets in the PC/VA composites and thus were unable to reinforce the material. The rheological measurements showed that now the viscosity of VA was higher than that of PC at 300°C. This structure development during the injection molding of these composites was manifested in the mechanical properties. The tensile modulus and tensile strength of the PC/VA composites were dependent on the processing temperature and on the VA concentrations. The modulus was maximum in the PC/VA blend with 20 wt % VA processed at 290°C. The Izod impact strength of the composites tended to markedly decrease with increasing VA content. The magnitude of the loss modulus decreased with increasing VA content at a given processing temperature. This was attributed to the anisotropic reinforcement of VA. Similarly, as the VA content increased, the modulus and thus the reinforcing effect were improved comparatively with the processing temperature increasing from 280 to 290°C; this, however, dropped in the case of composites processed at 300°C, at which the modulus anisotropy was reduced. Dynamic oscillatory shear measurements revealed that the viscoelastic properties, that is, the shear storage modulus and shear loss modulus, improved with decreasing processing temperatures and increasing VA contents in the composites. Also, the viscoelastic melt behavior (shear storage modulus and shear loss modulus) indicated that the addition of VA changed the distribution of the longer relaxation times of PC in the PC/VA composites. Thus, the injection‐molding processing temperature played a vital role in optimizing the morphology‐dependent mechanical properties of the polymer/LCP composites. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 2007     

Measurement and numerical simulation of three‐dimensional fiber orientation states in injection‐molded short‐fiber‐reinforced plastics

To determine three‐dimensional fiber orientation states in injection‐molded short‐fiber composites, a confocal laser scanning microscope (CLSM) is used. Since the CLSM optically sections the specimen, more than two images of the cross sections on and below the surface of the composite can be obtained. Three‐dimensional fiber orientation states can be determined by using geometric parameters of fiber images obtained from two parallel cross sections. For experiments, carbon‐fiber‐reinforced polystyrene is examined by the CLSM and geometric parameters of fibers on each cross‐sectional plane are measured by an image analysis. In order to describe fiber orientation states compactly, orientation tensors are determined at different positions of the prepared specimen. Three‐dimensional orientation states are obtained without any difficulty by determining the out‐of‐plane angles utilizing fiber images on two parallel planes acquired by the CLSM. Orientation states are different at different positions and show the shell–core structure along the thickness of the specimen. Fiber orientation tensors are predicted by a numerical analysis and the numerically predicted orientation states show good agreement with measured ones. However, some differences are found at the end of cavity. They may result from the fountain flow effects, which are not considered in the numerical analysis. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 500–509, 2003     

Real‐time ultrasonic monitoring of the injection‐molding process

In this study, a noninvasive and nondestructive ultrasonic technique has been used to monitor the polymer injection‐molding process in an attempt to establish a fundamental understanding of the processing/morphology/ultrasonic signal relationships. The ultrasonic technique not only can provide information on solidification affected by various temperatures and pressures but also can reflect the evolution of the crystal morphology and phase morphology of polymer blends. In addition, the periodic vibration of the dynamic‐packing injection‐molding process, in which the melt is forced to move repeatedly in a chamber by two pistons that move reversibly with the same frequency as the solidification progressively occurs from the mold wall to the molding core part, can also be monitored with the ultrasonic velocity and attenuation. Our results indicate that the ultrasonic technique is sensitive and promising for the real‐time monitoring of the injection‐molding process. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Mechanical properties and transparency of injection‐molded polyacetal with branched and linear structure: Influence of crystalline morphology

Branched and linear polyacetals prepared by cationic bulk polymerization were molded under high‐injection rate and pressure, and the resultant 1‐mm‐thick specimens were investigated regarding the crystalline morphology, mechanical properties, and transparency. The branched polyacetal exhibited shear‐induced transformation of crystalline morphology, namely, the spherulites, the elongated spherulites, and shish‐kebab morphology parallel to the flow direction, with increasing shear viscosity. The degree of orientation of the branched polyacetal, calculated from the intensity distribution on the Debye ring of the (100) diffraction by WAXS, linearly and significantly increased with the increase of the logarithm of the shear viscosity. The difference of the crystalline morphology greatly influenced the mechanical properties and transparency of the branched and linear polyacetals. The branched polyacetal with the shish‐kebab morphology had approximately 20% higher tensile strength and modulus as compared with those with the spherulites morphology, and showed translucent with a higher light transmittance over a wide range of wavelength of incident light. The results indicate that a large number of fibrous crystals in the shish‐kebab morphology result in the self‐reinforcement of specimens parallel to the flow direction and diminishment of the scattering of incident light. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 3182–3392, 2006