Drawing and extrusion of semi-crystalline polymers

Temperature-Dependent Polymorphism and Phase Transformation of Friction Transferred PLLA Thin Films

Poly(L-lactic acid) (PLLA) thin films with a highly oriented structure, successfully prepared by a fast friction transfer technique, were investigated mainly on the basis of synchrotron radiation wide-angle X-ray diffraction (WAXD) and Fourier transform infrared spectroscopy (FTIR). The crystalline structure of the highly oriented PLLA film was remarkably affected by friction transfer temperatures, which exhibited various crystal forms in different friction temperature regions. Interestingly, metastable β-form was generated at all friction transfer temperatures (70-140 °C) between T_g and T_m, indicating that fast friction transfer rate was propitious to the formation of β-form. Furthermore, the relative content among β-, α'-, and α-forms at different friction temperatures was estimated by WAXD as well as FTIR spectroscopy. In situ temperature-dependent WAXD was applied to reveal the complicated phase transition behavior of PLLA at a friction transfer temperature of 100 °C. The results illustrated that the contents of β- and α'-forms decreased in turn, whereas the α-form increased in content due to partially melt-recrystallization or crystal perfection. Moreover, by immersing into a solvent of acetone, β-, α'-form were transformed into stable α-crystalline form directly as a consequence. The highly oriented structure was maintained with the chain perfectly parallel to friction transfer direction after acetone treatment, evidenced by polarized FTIR and polarized optical microscopy (POM) measurements.

Thermally Drawn Highly Conductive Fibers with Controlled Elasticity

Electronic fabrics necessitate both electrical conductivity and, like any textile, elastic recovery. Achieving both requirements on the scale of a single fiber remains an unmet need. Here, two approaches for achieving conductive fibers (10⁷ S m^-1 ) reaching 50% elongation while maintaining minimal change in resistance (<0.5%) in embedded metallic electrodes are introduced. The first approach involves inducing a buckling instability in a metal microwire within a cavity of a thermally drawn elastomer fiber. The second approach relies on twisting an elastomer fiber to yield helical metal electrodes embedded in a stretchable yarn. The scalability of both approaches is illustrated in apparatuses for continuous buckling and twisting that yield tens of meters of elastic conducting fibers. Through experimental and analytical methods, it is elucidated how geometric parameters, such as buckling pre-strain and helical angle, as well as materials choice, control not only the fiber's elasticity but also its Young's modulus. Links between mechanical and electrical properties are exposed. The resulting fibers are used to construct elastic fabrics that contain diodes, by weaving and knitting, thus demonstrating the scalable fabrication of conformable and stretchable antennas that support optical data transmission.

Effect of the Elongational Flow on the Morphology and Properties of Polymer Systems: A Brief Review

Polymer-processing operations with dominating elongational flow have a great relevance, especially in several relevant industrial applications. Film blowing, fiber spinning and foaming are some examples in which the polymer melt is subjected to elongational flow during processing. To gain a thorough knowledge of the material-processing behavior, the evaluation of the rheological properties of the polymers experiencing this kind of flow is fundamental. This paper reviews the main achievements regarding the processing-structure-properties relationships of polymer-based materials processed through different operations with dominating elongational flow. In particular, after a brief discussion on the theoretical features associated with the elongational flow and the differences with other flow regimes, the attention is focused on the rheological properties in elongation of the most industrially relevant polymers. Finally, the evolution of the morphology of homogeneous polymers, as well as of multiphase polymer-based systems, such as blends and micro- and nano-composites, subjected to the elongational flow is discussed, highlighting the potential and the unique characteristics of the processing operations based on elongation flow, as compared to their shear-dominated counterparts.

Inducing nano-confined crystallization in PLLA and PET by elastic melt stretching

Based on the widely studied poly(l-lactic acid) (PLLA) and polyethylene terephthalate (PET) that are brittle in their fully crystalline form, this Letter shows that they can be made to be super ductile, heat resistant and optically clear by creating nano-sized crystals while preserving the entanglement network. Atomic force microscopic images confirm the perceived nano-confined crystallization. Time-resolved X-ray scattering/diffraction measurements reveal the emergence of cold crystallization during either stress relaxation from large stepwise melt-stretching or annealing of pre-melt-stretched PLLA and PET above Tg. Mechanical tests show that these polymers in such a new state are rigid even well above Tg, e.g., at 100 °C.

Influence of the Solidification Process on the Mechanical Properties of Solid-State Drawn PCL/Sepiolite Nanocomposite Tapes

In this research, poly(ε-caprolactone) (PCL) was melt-mixed with sepiolite nanoclays in a twin-screw extruder. In a subsequent step, the extruded films were drawn in the solid state to highly oriented nanocomposite films or tapes. A twin-screw extruder equipped with a Sultzer mixer for improved mixing in combination with a bench top drawing unit was used to prepare oriented nanocomposite tapes of different sepiolite loading and draw ratios. In order to study the influence of the solidification step on the drawability of the materials, different cooling procedures were applied prior to drawing. Optical microscopy images showed that slow or fast solidification using different chill rolls settings (open or closed) for the cast films resulted in different morphological conditions for subsequent drawing. The addition of sepiolite nanofillers led to nucleation and faster crystallization kinetics and oriented tapes which deformed by homogenous deformation rather than necking. The addition of sepiolite significantly improved the mechanical properties of both undrawn and drawn PCL tapes and Young’s modulus (1.5 GPa) and tensile strength (360 MPa) for composites based on 4 wt% sepiolite were among the highest ever reported for PCL nanocomposites. Interestingly, samples cooled with open chill rolls (slow crystallization) showed the highest modulus while solidification with closed rolls (fast crystallization) showed the highest tensile strength after drawing.

Flow-Induced Crystallization in Polyethylene: Effect of Flow Time on Development of Shish-Kebab

The flow-induced formation and relaxation of the representative oriented shish-kebab structure were studied with synchrotron small-angle X-ray scattering (SAXS) method. The flow duration was varied from 2 to 6 s at an identical strain rate to reveal the effect of flow time on stability and dimension of formed shish. It was found that the short flow time of 2 s was able to generate shish during flow, which, however, relaxed during the isothermal process after cessation of flow. An increase in flow time can improve the shish stability and the long flow time of 6 s can generate the stable shish that nucleate the growth of kebab lamellae. In addition, the quantitative analysis of SAXS results showed that with increasing flow time from 2 to 6 s, the shish length increased from 242 to 574 nm, while the shish diameter remained around 34 nm. This detailed information of the formed shish-kebab structure can be used to shed light on their evolution that occurred during flow from 2 to 6 s, where shish grew at a longitudinal speed of around 80 nm/s, and there was an improvement in the stability and nucleation capability for kebab lamellae.

Recent advances in post-stretching processing of polymer films with in situ synchrotron radiation X-ray scattering

The stretch-induced structural evolution mechanism is a long-standing scientific question in the post-stretching processing of polymer films. X-ray scattering, especially a combination of small- and wide-angle X-ray scattering (SAXS/WAXS), provides a powerful method to study the hierarchical structure of polymer films. Recent advances in synchrotron radiation (SR) light sources and detection techniques allow one to measure the structural evolution of polymer films during post-stretching processing in real time with ultrahigh time resolution, which benefits the understanding on this topic. This review summarizes some recent investigations on post-stretching processing of polymer films, which combine in situ X-ray scattering techniques with purposely designed tensile apparatus in terms of three aspects: uniaxial stretching, biaxial stretching and stretching with chemical reactions. Concerning the polymer bulk, traditional deformation mechanisms like stretch-induced crystallization (SIC), crystal slipping, phase transition and melting-recrystallization are discussed for the uniaxial and biaxial post-stretching of polymer films. New deformation models have been developed to focus on the structural evolution on the length scale of lamellar stacks, which consider the potential microphase separation of the interlamellar amorphous phase and microbuckling. For solution systems, the coupled effects of the mechanical work from external force and the chemical potential from possible chemical reactions are taken into account for the structural evolution during stretching in solution. Roadmaps of structural and morphological evolution in the processing parameter space (i.e., temperature, stress, strain and the concentration of additive in the bath solution) are eventually constructed for precursor films. The accumulation of a structural evolution database for post-stretching processing of polymer films can be expected to provide a helpful guide for industrial processing for high-performance polymers in the near future.

Structure Evolution and Deformation Behavior of Polyethylene Film during Biaxial Stretching

The structure evolution and deformation behavior of tenter-frame biaxially oriented polyethylene (TF-BOPE) films were investigated in this study. For sequential biaxial stretching, the original spherulites were broken into small pieces, and the fibrillar structure simultaneously formed during the machine direction (MD) stretching. Subsequently, the single fibrils were pulled away, and some fine fibrils developed via partial melting-recrystallization or lamellar rearrangement during the transverse direction (TD) stretching, which leads to the formation of the vein structure and nanosized fiber-like network. For simultaneous biaxial stretching, the fractured lamellae and the newly formed crystals were evenly distributed in the MD-TD plane like an isotropous fibrillar network. Moreover, compared with the unstretched sample, both films could achieve up to about 2 times the tensile modulus and 4.5 times the tensile strength and also exhibited the superior optical property.

Method and Mathematical Modeling of Formation of Gradually and Homogeneously Oriented Linear Polymers

Previously, we developed several technical solutions for the conversion of isotropic polymers into materials of a new type—gradually oriented polymers with a gradient of physical and mechanical properties, thereby materializing for the first time the unused possibilities inherent in the polymeric nature of the substance. The scientific basis of these developments is the concept of a new structural state of linear polymers—a gradually oriented (stretched) state (GOS), the essence of which is set out briefly. An algorithm and a mathematical model for controlling the process of uniaxial, zonal stretching of linear polymers are proposed, which allow the formation of gradually or homogeneously oriented polymers (polymer composites). At the same time, specified values of quantitative parameters are ensured, in particular, the selected profile of distribution of the relative elongation (linear, sinusoidal, etc.) along the length of the gradually oriented polymer sample and the specified constant relative elongation along the length of the homogeneously oriented polymer. Mathematical expressions for calculating the conditions to obtain gradually oriented polymers with given geometric dimensions (length, width) and with a given distribution of relative elongation along the length of the resulting sample were also derived. The description of method and principles of operation of the appropriate device is given. Experimental data illustrating the possibilities of the proposed method and the efficiency of mathematical modeling are presented. The issues of creating functionally graded materials with a gradient of microstructure (gradient of degree of orientation/relative elongation) or chemical composition (volume fraction of functional fillers), respectively, based on thermoplastic polymer/copolymer or polymer composite (containing functional fillers) by method of uniaxial, zonal graded stretching are discussed.

Nanostructured polymer films with metal-like thermal conductivity

Due to their unique properties, polymers - typically thermal insulators - can open up opportunities for advanced thermal management when they are transformed into thermal conductors. Recent studies have shown polymers can achieve high thermal conductivity, but the transport mechanisms have yet to be elucidated. Here we report polyethylene films with a high thermal conductivity of 62 Wm-1 K-1, over two orders-of-magnitude greater than that of typical polymers (~0.1 Wm-1 K-1) and exceeding that of many metals and ceramics. Structural studies and thermal modeling reveal that the film consists of nanofibers with crystalline and amorphous regions, and the amorphous region has a remarkably high thermal conductivity, over ~16 Wm-1 K-1. This work lays the foundation for rational design and synthesis of thermally conductive polymers for thermal management, particularly when flexible, lightweight, chemically inert, and electrically insulating thermal conductors are required.

Thermal Conductivity of Protein-Based Materials: A Review

Fibrous proteins such as silks have been used as textile and biomedical materials for decades due to their natural abundance, high flexibility, biocompatibility, and excellent mechanical properties. In addition, they also can avoid many problems related to traditional materials such as toxic chemical residues or brittleness. With the fast development of cutting-edge flexible materials and bioelectronics processing technologies, the market for biocompatible materials with extremely high or low thermal conductivity is growing rapidly. The thermal conductivity of protein films, which is usually on the order of 0.1 W/m·K, can be rather tunable as the value for stretched protein fibers can be substantially larger, outperforming that of many synthetic polymer materials. These findings indicate that the thermal conductivity and the heat transfer direction of protein-based materials can be finely controlled by manipulating their nano-scale structures. This review will focus on the structure of different fibrous proteins, such as silks, collagen and keratin, summarizing factors that can influence the thermal conductivity of protein-based materials and the different experimental methods used to measure their heat transfer properties.

Evolution of cellular morphologies and crystalline structures in high-expansion isotactic polypropylene/cellulose nanofiber nanocomposite foams

Herein, the development of cell morphology and crystalline microstructure of injection-molded isotactic polypropylene/cellulose nanofiber (PP/CNF) composite foams with 2-10-fold expansion ratios was investigated through scanning electron microscopy (SEM), wide-angle X-ray diffraction (WAXD), and small-angle X-ray scattering (SAXS). Compared with isotactic polypropylene (iPP) foams, the added CNF improved the cell morphology and resulted in a great reduction in cell size. Additionally, the PP lamella orientation and crystal type were notably altered during the core-back FIM process. As the expansion ratio increased, the original isotropic lamellae in the iPP foams were transformed into an oriented lamellar structure and then further transformed into a typical shish-kebab structure, while hybrid shish-kebab structures were simultaneously generated in the high-expansion PP/CNF nanocomposite foams. Accordingly, the highest content of β-crystals was observed in the low-expansion iPP foams. In contrast, the β-crystal content in PP/CNF composites decreased monotonously as the expansion ratio increased, which resulted from the combined effects of CNF's nucleating ability for α-crystals and the more dominant extensional flow effect assisted by the added CNF.

Oxidation Reactions in Kink Banded Regions of UHMMPE Fiber-Based Laminates Used in Body Armor: A Mechanistic Study

This work demonstrates the synergy between the thermo-mechanical and humidity induced degradation as well as the oxidation reactions in the kink-banded areas of ultra-high molar mass polyethylene (UHMMPE) fiber-based laminates used in body armor. For aged materials, the energy-dispersive X-ray spectroscopy (EDS) and Fourier transform infrared spectroscopy (FTIR) results reveal high concentrations of oxygen containing products, and the EPR results demonstrate the presence of the peroxyl radicals (RO₂ ^• ) in the kink-banded areas. After one year of dark ambient storage, very long-lived RO₂ ^• radicals were observed primarily in the samples exposed to ageing conditions of elevated temperatures, humidity, and mechanical stress. The total percentage of crystallinity, as measured by differential scanning calorimetry, of the kinkbanded fibers was unchanged, indicating that the degradation occurs primarily in the amorphous region, and may also involve recrystallization processes of the degraded chains. However, the most abundant orthorhombic crystalline phase decreases from 77 % to 70 %. This decrease in the orthorhombic structure leads to more diffusion of oxygen into the kink-banded region, enhancing the oxidation processes. No changes are observed in the monoclinic phase of the kinked fibers, which remained constant and constituted ~2 % of the total crystallinity.

Structural and morphological transitions in extension-induced crystallization of poly(1-butene) melt

Structural and morphological transitions of flow-induced crystallization (FIC) in poly(1-butene) (PB-1) melt have been studied by combining extensional rheology and in situ synchrotron radiation ultrafast wide- and small-angle X-ray scattering (WAXD/SAXS) measurements. Unexpectedly, metastable Form III is crystallized directly from the PB-1 melt by high-speed extension, which has a short lifetime of several tens of milliseconds and manifests the thermodynamic and kinetic competition among Form III, Form II and melt under flow. Relative crystallinity evolution of Form II after extension reveals a crystal melting dominated process within the observation time of 120 s even under high supercooling. This is opposite to the common case of FIC but supports the idea that flow alters the obtained crystal size and its thermodynamic stability. Additionally, a morphological transition from a flow-induced network to shish is observed by SAXS with increasing extension temperature from below to above the melting point of Form II. With above observations, we construct nonequilibrium structural and morphological diagrams of FIC in strain rate-temperature space, which may guide the industrial processing of the PB-1 material.

Preparation of High Modulus Poly(Ethylene Terephthalate): Influence of Molecular Weight, Extrusion, and Drawing Parameters

Poly(ethylene terephthalate) (PET) which is one of the most commercially important polymers, has for many years been an interesting candidate for the production of high performance fibres and tapes. In current study, we focus on investigating the effects of the various processing variables on the mechanical properties of PET produced by a distinctive process of melt spinning and uniaxial two-stage solid-state drawing (SSD). These processing variables include screw rotation speed during extrusion, fibre take-up speed, molecular weight, draw-ratio, and drawing temperature. As-spun PET production using a single-screw extrusion process was first optimized to induce an optimal polymer microstructure for subsequent drawing processes. It was found that less crystallization which occurred during this process would lead to better drawability, higher draw-ratio, and mechanical properties in the subsequent SSD process. Then the effect of drawing temperature (DT) in uniaxial two-stage SSD process was studied to understand how DT (<Tg or close to Tg or close to Trec) would affect the crystallization, draw-ratio, and final mechanical properties of PET. The designed process in current work is simulated to an industrial production process for PET fibres; therefore, results and analysis in this paper have significant importance for industrial production.

The Effect of Thermal History on the Fast Crystallization of Poly(l-Lactide) with Soluble-Type Nucleators and Shear Flow

The N₁,N₁'-(ethane-1,2-diyl)bis(N₂-phenyloxalamide) (OXA) is a soluble-type nucleator with a dissolving temperature of 230 °C in poly(l-lactic acid) (PLLA) matrix. The effect of thermal history and shear flow on the crystallization behavior of the PLLA/OXA samples was investigated by rheometry, polarized optical microscopy (POM), differential scanning calorimetry (DSC), wide angle X-ray diffraction (WAXD), and scanning electron microscopy (SEM). The crystallization process of the PLLA/OXA-240 sample (i.e., pre-melted at 240 °C) was significantly promoted by applying a shear flow, e.g., the onset crystallization time (tonset) of the PLLA at 155 °C was reduced from 1600 to 200 s after shearing at 0.4 rad/s for even as short as 1.0 s, while the crystallinity (Xc) was increased to 40%. Moreover, the tonset of the PLLA/OXA-240 sample is 60%⁻80% lower than that of the PLLA/OXA-200 sample (i.e., pre-melted at 200 °C) with a total shear angle of 2 rad, indicating a much higher crystallization rate of the PLLA/OXA-240 sample. A better organization and uniformity of OXA fibrils can be obtained due to a complete pre-dissolution in the PLLA matrix followed by shear and oscillation treatments. The well dispersed OXA fibrils and flow-induced chain orientation are mainly responsible for the fast crystallization of the PLLA/OXA-240 samples. In addition, the shear flow created some disordered α'-form crystals in the PLLA/OXA samples regardless of the thermal history (200 or 240 °C).

Lamellae evolution of poly(butylene succinate-co-terephthalate) copolymer induced by uniaxial stretching and subsequent heating

The structural evolution of biodegradable poly(butylene succinate-co-terephthalate) copolymer was investigated during the uniaxial stretching and following heating processes via in situ small-angle X-ray scattering.