Structural morphology and compaction of nascent high-density polyethylene produced by supported catalysts

The morphologies of three nascent high-density polyethylene (HDPE) powders, polymerized in the gas phase by different catalysts, were investigated using scanning electron microscopy (SEM). Silica-supported catalyst systems comprising TiCl₄/MgCl₂,bis(triphenylsilyl)chromate andbis(cyclopentadienyl)chromium were found to produce polymers with globular, nodular and worm-like microstructures, respectively. The topographies of the fluff particles are related to the compaction behaviour of the HDPE powders. Long, worm-like strands that protrude from the particles are capable of forming more extensive entanglements than the shorter, nodular structures. The entanglements are the main cause of agglomeration of the particles during their long-term bulk storage. Furthermore, the rate of thermal oxidation is influenced markedly by the polymer microstructure. The microstructure determines the surface area available for oxygen attack. High-resolution SEM combined with low-temperature plasma etching reveals that the worm-like structures consist of folded-chain lamellae that are coiled around a core of extended chains.