Molecular Structure, Phase Composition, Melting Behavior, and Chain Entanglements in the Amorphous Phase of High-Density Polyethylenes

Ultra-Strong Protein-Based Hydrogels via Promoting Intermolecular Entanglement of the Amorphous Region

Proteins are classified as biopolymers which share similar structural features with semi-crystalline polymers. Although their unique biocompatibility facilitates the universal applications of protein-based hydrogels in the biomedical field, the mechanical performances of protein-based hydrogels fall short of practical requirements. Conventional strategies for enhancing mechanical properties focus on forming regularly folded secondary structures as analogs of crystalline regions. This concept is based on proteins as the analogy of semi-crystalline polymers, in which crystalline regions profoundly contribute to the mechanical performances. Even though the contribution of the amorphous region is equally weighted for semi-crystalline polymers, their capacity to improve the mechanical performances of protein-based structures is still undervalued. Herein, the potential of promoting the mechanical performances is explored by controlling the state of amorphous regions in protein-based hydrogels. A fibril protein is chosen, regenerated silk fibroin (RSF), as a model molecule for its similar viscoelasticity with a semi-crystalline polymer. The amorphous regions in the RSF hydrogels are transformed from extended to entangled states through a double-crosslinking method. The formation of entanglement integrates new physically crosslinked points for remarkable improvement in mechanical performances. A robust hydrogel is not only developed but also intended to provide new insights into the structural-property relationship of protein-based hydrogels.

Polymer Physics behind the Gel-Spinning of UHMWPE Fibers

Gel-spinning of ultra-high molecular weight polyethylene (UHMWPE) fibers has attracted great interest in academia and industry since its birth and commercialization in the 1980s, due to unique properties such as high modulus, low density, and excellent chemical resistance. However, the high viscosity and long relaxation time greatly complicate processing. In industry, solvents, like decalin and paraffin oil, usually disentangle the physical networks and promote final drawability. From extruding the polymer solution to post-solid-stretching, many polymer physics problems that accompany high-modulus fiber gel-spinning should be understood and addressed. In this review, by detailed discussions about the effect of entanglements and intracrystalline chain dynamics on the mechanical properties of UHMWPE, theoretical descriptions of the structure formation of disentangled UHMWPE crystals, and the origin of high modulus and strength of final fibers are provided. Several physical intrinsic key factors are also discussed, revealing why UHMWPE is an ideal material for producing high-performance fibers.

Closed-Loop Recyclable and Nonpersistent Polyethylene-like Polyesters

ConspectusAliphatic polyesters based on long-chain monomers were synthesized for the first time almost a century ago. In fact, Carothers' seminal observations that founded the entire field of synthetic polymer fibers were made on such a polyester sample. However, as materials, they have evolved only over the past decade. This is driven by the corresponding monomers becoming practically available from advanced catalytic conversions of plant oils, and future prospects comprise a possible generation from third-generation feedstocks, such as microalgae or waste. Long-chain polyesters such as polyester-18.18 can be considered to be polyethylene chains with a low density of potential breakpoints in the chain. These do not compromise the crystalline structure or the material properties, which resemble linear high-density polyethylene (HDPE), and the materials can also be melt processed by injection molding, film or fiber extrusion, and filament deposition in additive manufacturing. At the same time, they enable closed-loop chemical recycling via solvolysis, which is also possible in mixed waste streams containing polyolefins and even poly(ethylene terephthalate). Recovered monomers possess a quality that enables the generation of recycled polyesters with properties on par with those of the virgin material. The (bio)degradability varies enormously with the constituent monomers. Polyesters based on short-chain diols and long-chain dicarboxylates fully mineralize under industrial composting conditions, despite their HDPE-like crystallinity and hydrophobicity. Fundamental studies of the morphology and thermal behavior of these polymers revealed the location of the in-chain groups and their peculiar role in structure formation during crystallization as well as during melting. All of the concepts outlined were extended to, and elaborated on further, by analogous long-chain aliphatic polymers with other in-chain groups such as carbonates and acetals. The title materials are a potential solution for much needed circular closed-loop recyclable plastics that also as a backstop if lost to the environment will not be persistent for many decades.

Chain Dynamics of Partially Disentangled UHMWPE around Melting Point Characterized by 1H Low-Field Solid-State NMR

Melts of ultrahigh molecular weight polyethylene (UHMWPE) entangled significantly, suffering processing difficulty. In this work, we prepared partially disentangled UHMWPE by freeze-extracting, exploring the corresponding enchantment of chain mobility. Fully refocused ¹H free induction decay (FID) was used to capture the difference in chain segmental mobility during the melting of UHMWPE with different degrees of entanglement by low-field solid-state NMR. The longer the polyethylene (PE) chain is in a less-entangled state, the harder the process of merging into mobile parts after detaching from crystalline lamella during melting. ¹H double quantum (DQ) NMR was further used to obtain information caused by residual dipolar interaction. Before melting, the DQ peak appeared earlier in intramolecular-nucleated PE than in intermolecular-nucleated PE because of the strong constraints of crystals in the former one. During melting, less-entangled UHMWPE could keep disentangled while less-entangled high density polyethylene (HDPE) could not. Unfortunately, no noticeable difference was found in DQ experiments between PE melts with different degrees of entanglement after melting. It was ascribed to the small contribution of entanglements compared with total residual dipolar interaction in melts. Overall, less-entangled UHMWPE could reserve its disentangled state around the melting point long enough to achieve a better way of processing.

Evidence for complexation-induced micro-extension of poly(vinyl alcohol) chains in interphase and amorphous domains from solid-state NMR

The three-phase structure of poly(vinyl alcohol) (PVA)-iodine complexes was elucidated by solid-state NMR (SSNMR), of which the micro-extension of the PVA segment in the interphase and amorphous domains was directly confirmed. The three-phase structure of the PVA-iodine complex was decomposed by the inverse ¹³C T₁-filter, where ¹³C NMR resonance lines of a C(H) triplet were observed in all three phases. The chain axis of ∼26% extended chains in the interphase deviates 35°-50° relative to the stretching direction, while there is only a 1° deviation for the extended chains in the crystalline domain. The increasing iodine concentration results in the increment of hydrogen-bonded C(H) fractions in both the amorphous and interphase domains, while the distribution of different C(H) fractions remains almost constant in the crystalline domain. Such an increment results from the locally extended PVA chains induced by polyiodine species (I₃^-/I₅^-), since the hydrogen bond(s) (HBs) required a specific direction. Direct evidence for this comes from the similar ¹³C CP/MAS spectra of C(H) in the three phases between unoriented iodine-doped PVA and highly oriented pure PVA. This supports the aggregation model for the formation mechanism of PVA-iodine complexes, where the PVA chain takes an extended zig-zag conformation.

A New Look at the Structure and Thermal Behavior of Polyvinylidene Fluoride-Camphor Mixtures

An experimental quasi-equilibrium phase diagram of the polyvinylidene fluoride (PVDF)-camphor mixture is constructed using an original optical method. For the first time, it contains a boundary curve that describes the dependence of camphor solubility in the amorphous regions of PVDF on temperature. It is argued that this diagram cannot be considered a full analogue of the eutectic phase diagrams of two low-molar-mass crystalline substances. The phase diagram is used to interpret the polarized light hot-stage microscopy data on cooling the above mixtures from a homogeneous state to room temperature and scanning electron microscopy data on the morphology of capillary-porous bodies formed upon camphor removal. Based on our calorimetry and X-ray studies, we put in doubt the possibility of incongruent crystalline complex formation between PVDF and camphor previously suggested by Dasgupta et al. (Macromolecules 2005, 38, 5602-5608). We also describe and discuss the high-temperature crystalline structure of racemic camphor, which is not available in the modern literature.

Additive Manufacturing of Polyolefins

Polyolefins are semi-crystalline thermoplastic polymers known for their good mechanical properties, low production cost, and chemical resistance. They are amongst the most commonly used plastics, and many polyolefin grades are regarded as engineering polymers. The two main additive manufacturing techniques that can be used to fabricate 3D-printed parts are fused filament fabrication and selective laser sintering. Polyolefins, like polypropylene and polyethylene, can, in principle, be processed with both these techniques. However, the semi-crystalline nature of polyolefins adds complexity to the use of additive manufacturing methods compared to amorphous polymers. First, the crystallization process results in severe shrinkage upon cooling, while the processing temperature and cooling rate affect the mechanical properties and mesoscopic structure of the fabricated parts. In addition, for ultra-high-molecular weight polyolefins, limited chain diffusion is a major obstacle to achieving proper adhesion between adjunct layers. Finally, polyolefins are typically apolar polymers, which reduces the adhesion of the 3D-printed part to the substrate. Notwithstanding these difficulties, it is clear that the successful processing of polyolefins via additive manufacturing techniques would enable the fabrication of high-end engineering products with enormous design flexibility. In addition, additive manufacturing could be utilized for the increased recycling of plastics. This manuscript reviews the work that has been conducted in developing experimental protocols for the additive manufacturing of polyolefins, presenting a comparison between the different approaches with a focus on the use of polyethylene and polypropylene grades. This review is concluded with an outlook for future research to overcome the current challenges that impede the addition of polyolefins to the standard palette of materials processed through additive manufacturing.

Verification of the Influence of Processing History through Comparing High-Speed Melt Spinning Behavior of Virgin and Recycled Polypropylene

A ‘model’ material of recycled polypropylene (PP) was prepared through the injection molding process, and the effect of processing history on the polymer characteristics was investigated through the high-speed melt spinning of virgin and recycled PP. On-line measurement of the thinning behavior of the spin-line revealed the downstream shift of solidification point for the recycled PP at the take-up velocity of 1.0 km/min, indicating the suppression of flow-induced crystallization. The difference was not clear at higher take-up velocities of up to 5 km/min. For any identical take-up velocity, no clear difference in the stress-strain curves and birefringence of the fibers from virgin and recycled PP could be observed, whereas the detailed investigation on the variation of relative amount of c-axis and a*-axis oriented crystals in the fibers prepared at varied take-up velocities suggested the deterioration of flow-induced crystallization at 1.0 km/min. It was speculated that the processing history induced the lowering of the entanglement density, which affected the melt spinning and crystallization behavior. An undistinguishable difference between the virgin and recycled PP at increased take-up velocities suggested the existence of an optimum elongational strain rate for the detection of the different states of molecular entanglement.

Dynamic heterogeneity in homogeneous polymer melts

Chain entanglement behaviors were studied by 1H Hahn echo nuclear magnetic resonance (NMR) and 1H double-quantum (DQ) NMR experiments. Poly(ethylene oxide) (PEO) was chosen to investigate the chain entanglement behaviors. The 1H Hahn echo NMR results demonstrate that the critical molecular weight of PEO is approximately 6 kg mol-1. Above this critical molecular weight, chain entanglements start to occur in the melts resulting in anisotropic motions of polymer chain. The 1H DQ NMR observations establish that PEO melts with molecular weights above the critical value exhibit dynamical entanglements. The entangled networks, formed by PEO with a molecular weight of 480 kg mol-1 (PEO480), present slow mobility and rather homogeneously distributed chain entanglements, while the entangled networks, formed by PEO with a molecular weight of 255 kg mol-1 (PEO255), present fast mobility and obvious dynamic heterogeneity in the distribution of chain entanglement. Short chain PEOs like that with a molecular weight of 2 kg mol-1 are demonstrated to function like solvents when being added in an appropriate concentration to PEO480, and the dilution effect increases the chain mobility of PEO480. Moreover, properly diluted PEO480 networks exhibit dynamic heterogeneity similar to that observed in PEO255.