Deformation behavior of oriented β-crystals in injection-molded isotactic polypropylene by in situ X-ray scattering

Insights on the Molecular Behavior of Polypropylene in the Process of Ultrasonic Injection Molding

Product miniaturization is a constant trend in industries that demand ever-smaller products that can be mass produced while maintaining high precision dimensions in the final pieces. Ultrasonic micro injection molding (UMIM) technology has emerged as a polymer processing technique capable of achieving the mass production of polymeric parts with micro-features, while still assuring replicability, repeatability, and high precision, contrary to the capabilities of conventional processing technologies of polymers. In this study, it is shown that the variation of parameters during the UMIM process, such as the amplitude of the ultrasound waves and the processing time, lead to significant modification on the molecular structure of the polymer. The variation of both the amplitude and processing time contribute to chain scission; however, the processing time is a more relevant factor for this effect as it is capable of achieving a greater chain scission in different areas of the same specimen. Further, the presence of polymorphism within the samples produced by UMIM is demonstrated. Similarly to conventional processes, the UMIM technique leads to some degree of chain orientation, despite the fact that it is carried out in a relatively small time and space. The results presented here aim to contribute to the optimization of the use of the UMIM process for the manufacture of polymeric micro parts.

Morphology and Isothermal Crystallization Kinetics of Polypropylene/Poly(ethylene-co-vinyl alcohol) Blends

Polypropylene (PP)/poly(ethylene-co-vinyl alcohol) (EVOH) blends were prepared by melt blending using PP-g-MAH as a compatabilizer. The microstructure and rheological behavior of PP/EVOH blends were studied. The results showed the that EVOH particles were uniformly dispersed in the PP matrix and inhibited the mobility of PP chains. The isothermal crystallization kinetics and morphology development of PP/EVOH blends were compared with that of pure PP. It was found that the EVOH essentially acted as an effective nucleating agent for PP, which could significantly increase the nucleation rate because the EVOH molecules in PP/EVOH blends aggregated together to form interface. Therefore, the introduction of EVOH increased the overall rate of isothermal crystallization compared with pure PP, although the PP molecular chains would be hindered seriously if excessive amounts of EVOH were added. X-ray diffraction showed that pure PP and PP/EVOH blends exhibited an identical crystal structure, and the crystallinity of the PP phase in the blends was not significantly different from that of pure PP.

Hierarchical Structure of iPP During Injection Molding Process with Fast Mold Temperature Evolution

Mold surface temperature strongly influences the molecular orientation and morphology developed in injection molded samples. In this work, an isotactic polypropylene was injected into a rectangular mold, in which the cavity surface temperature was properly modulated during the process by an electrical heating device. The induced thermo-mechanical histories strongly influenced the morphology developed in the injection molded parts. Polarized optical microscope and atomic force microscope were adopted for morphological investigations. The combination of flow field and cooling rate experienced by the polymer determined the hierarchical structure. Under strong flow fields and high temperatures, a tightly packed structure, called shish-kebab, aligned along the flow direction, was observed. Under weak flow fields, the formation of β-phase, as cylindrites form, was observed. The formation of each morphological structure was analyzed and discussed on the bases of the flow and temperature fields, experienced by the polymer during each stage of the injection molding process.

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

The development of cell morphology and crystalline microstructure of high expansion injection-molded isotactic polypropylene/cellulose nanofiber (PP/CNF) nanocomposite foams was understood.