Tailored Nanostructured HDPE Wax/UHMWPE Reactor Blends as Additives for Melt-Processable All-Polyethylene Composites and in Situ UHMWPE Fiber Reinforcement

Crystallographic Texture Evolution in 3D Printed Polyethylene Reactor Blends

In this work, crystallographic texture evolution in 3D printed trimodal polyethylene (PE) blends and high-density PE (HDPE) benchmark material were investigated to quantify the resulting material anisotropy, and the results were compared to materials made from conventional injection molded (IM) samples. Trimodal PE reactor blends consisting of HDPE, ultrahigh molecular weight PE (UHMWPE), and HDPE_wax have been used for 3D printing and injection molding. Changes in the preferred orientation and distribution of crystallites, i.e., texture evolution, were quantified utilizing the wide angle X-ray diffraction through pole figures and orientation distribution functions (ODFs) for 3D printed and IM samples. Since the change in weight-average molecular weight (Mw) of the blend was expected to significantly affect the resulting crystallinity and orientation, the overall Mw of the trimodal PE blend was varied while keeping the UHMWPE component weight fraction to 10% in the blend. The resulting texture was analyzed by varying the overall Mw of the trimodal blend and the process parameters in 3D printing and compared to the texture of conventional IM samples. The printing speed and orientation (defined with respect to the axis along the length of the samples) were used as the variable process parameters for 3D printing. The degree of anisotropy increases with an increase in the nonuniform distribution of intensities in pole figures and ODFs. All the highest intensity major texture components in IM and 3D printed samples (0° printing orientation) of reactor blends are observed to have crystals oriented in [001] or [001̅]. Overall, for the same throughput, 3D printed samples in the 0° orientation showed greater texture evolution and higher anisotropy compared to IM samples. Most notably, an increase in 3D printing speed increased the crystalline distribution closer to the 0° direction, increasing the anisotropy, while deviation from this printing orientation reduced crystalline distribution closer to the 0° direction, thus increasing isotropy. This demonstrates that tailoring material properties in specific directions can be achieved more effectively with 3D printing than with the injection molding process. Change in the overall Mw of the trimodal PE blend changed the preferential orientation distribution of the crystal planes to some degree. However, the degree of anisotropy remained the same in almost all cases, indicating that the effect of molecular weight distribution is not as significant as the printing speed and printing orientation in tailoring the resulting properties. The 3D printing process parameters (speed and orientation) were shown to have more influence on the texture than the material parameters associated with the blend.

Revealing the Effect of the Molecular Weight Distribution on the Chain Diffusion and Crystallization Process under a Branched Trimodal Polyethylene System

With the increasing demand for high-end materials, trimodal polyethylene (PE) has become a research hotspot in recent years due to its superior performance compared with bimodal PE. By means of molecular dynamics (MD) simulations, we aim to expound the effect of the molecular weight distribution (MWD) on the mechanism of nucleation and crystallization of trimodal PE. The crystallization rate is faster when short-chain branching is distributed on a single backbone compared to that on two backbones. In addition, as the content of high molecular weight backbone decreases, the time required for nucleation decreases, but the crystallization rate slows down. This is because low molecular weight backbones undergo intra-chain nucleation and crystallize earlier due to the high diffusion capacity, which leads to entanglement that prevents the movement of medium or high molecular weight backbones. Furthermore, crystallized short backbones hinder the movement and crystallization of other backbones. What is more, a small increase in the high molecular weight branched backbone of trimodal PE can make the crystallinity greater than that of bimodal PE, but when the content of high molecular weight backbone is too high, the crystallinity decreases instead, because the contribution of short and medium backbones to high crystallinity is greater than that of long backbones.

Effect of Nano-SiO2 on Different Stages of UHMWPE/HDPE Fiber Preparation via Melt Spinning

Ultra-high molecular weight polyethylene (UHMWPE)/high-density polyethylene (HDPE) blend with lower viscosity is more suitable for melt spinning compared to pure UHMWPE; however, the mechanical property of the blend fiber is hard to dramatically improve (the maximum tensile strength of 998.27 MPa). Herein, different content modified-nano-SiO₂ is incorporated to UHMWPE/HDPE blend fiber. After adding 0.5 wt% nano-SiO₂, the tensile strength and initial modulus of UHMWPE/HDPE/nano-SiO₂ fiber are increased to 1211 MPa and 12.81 GPa, respectively, 21.57% and 43.32% higher than that of UHMWPE/HDPE fiber. Meanwhile, the influence of the nano-SiO₂ content on the performance for as-spun filament and fiber are emphatically analyzed. The crystallinity and molecular chain orientation of as-spun filament reduces with the addition of nano-SiO₂. On the contrary, for fiber, the addition of nano-SiO₂ promoted the crystallinity, molecular chain orientation and grain refinement more obvious at a lower content. Furthermore, the possible action mechanism of nano-SiO₂ in the as-spun filament extrusion and fiber hot drawing stage is explained.

Fabric Insert Injection Molding for the Preparation of Ultra-High Molecular Weight Polyethylene/High-Density Polyethylene Two-Component Self-Reinforced Composites

The fabric insert injection molding approach can be applied to produce easily recyclable self-reinforced polymer composites (SrCs) whose reinforcement and matrix are from the same polymer. However, the mechanical properties of the SrCs are usually limited due to the poor impregnation of the inserted fabric. In this work, the ultra-high molecular weight polyethylene (UHMWPE) fabrics were used as the insert, and the high-density polyethylene (HDPE) melt was injected to fill the mold cavity and impregnate the fabrics. The UHMWPE/HDPE two-component SrCs were prepared. The large difference of melting temperatures between UHMWPE and HDPE can establish a wide processing temperature window, and thus the impregnation of the fabric can be improved by increasing temperature. The tensile strength and modulus of the UHMWPE/HDPE SrCs were up to 148 and 1132 MPa, respectively. The peel strength could be up to 35.2 N/cm. The influences of four main injection molding parameters, including the injection temperature, injection pressure/packing pressure, injection velocity, and packing time, were investigated. The temperature, pressure, viscosity, and density of the matrix in the mold cavity were calculated by the numerical simulation to indicate the impregnation process during the fabric insert injection molding process.

The Stronger the Better: Donor Substituents Push Catalytic Activity of Molecular Chromium Olefin Polymerization Catalysts

The donor strength of bifunctional pyridine-cyclopentadienyl ligands was altered systematically by the introduction of donating groups in the para-position of the pyridine. In the resulting chromium complexes an almost linear correlation between donor strength and the nitrogen-chromium distance as well as the electronic absorption maximum is experimentally observed. The connection of electron-donating groups in the ligand backbone leads to an efficient transfer of the electronic influences to the catalytically active metal centre without restricting it through steric effects. Therefore, catalytic olefin polymerization activity, which is already very high for the previously studied catalysts, increase considerably by attaching para-amino groups to the chelating pyridine or quinoline, respectively. Combining electron-rich indenyl ligands with para-amino substituted pyridines lead to the highest catalytic activities observed so far for this class of organo chromium olefin polymerisation catalysts. The resulting polymers are of ultra-high molecular weight and the ability of the catalysts to incorporate co-monomers is also very high.

The Structural and Mechanical Properties of the UHMWPE Films Mixed with the PE-Wax

Since obtaining a highly oriented structure based on a large-scale commercial ultra-high molecular weight polyethylene (UHMWPE) is considered very difficult due to its high molecular weight and melting index, modifying the structure of these cheap commercial UHMWPE brands into a supra-molecular structure with fiber-forming properties by adding a small amount of polyethylene wax (PE-wax) will provide the possibility to obtain highly oriented UHMWPE products with enhanced mechanical and tribological properties. In this work, highly oriented UHMWPE/PE-wax films were prepared. The PE-wax affected the UHMWPE as an intermolecular lubricant. The obtained lamellar structure of the UHMWPE/PE-wax composites had a better processability. The UHMWPE and UHMWPE/PE-wax structures for the xerogels and the films were studied by using differential scanning calorimetry and scanning electron microscopy. The PE-wax presence enhanced the mechanical properties of the UHMWPE/PE-wax films to a high degree. The highest average value of the tensile strength was 1320 MPa (an increase of 78%) obtained by adding a PE-wax content of 1.0 wt.%, and the highest average value of the Young’s modulus was 56.8 GPa (an increase of 71%) obtained by adding a PE-wax content of 2.0 wt.%. The addition of the PE-wax increased the work of fracture values of the UHMWPE/PE-wax films up to 233%. The formation of the cavities was observed in the virgin UHMWPE films more than in the UHMWPE/PE-wax films, and the whitening of the oriented films was related to the crystallization process more than to the cavitation phenomenon. The coefficient of friction of the oriented UHMWPE/PE-wax films improved by 33% in comparison with the isotropic UHMWPE, and by 7% in comparison with the oriented virgin UHMWPE films.

Tailoring Hydrocarbon Polymers and All-Hydrocarbon Composites for Circular Economy

The world population will rapidly grow from 7 to 9 billion by 2050 and this will parallel a surging annual plastics consumption from today's 350 million tons to well beyond 1 billion tons. The switch from a linear economy with its throwaway culture to a circular economy with efficient reuse of waste plastics is therefore mandatory. Hydrocarbon polymers, accounting for more than half the world's plastics production, enable closed-loop recycling and effective product-stewardship systems. High-molar-mass hydrocarbons serve as highly versatile, cost-, resource-, eco- and energy-efficient, durable lightweight materials produced by solvent-free, environmentally benign catalytic olefin polymerization. Nanophase separation and alignment of unentangled hydrocarbon polymers afford 100% recyclable self-reinforcing all-hydrocarbon composites without requiring the addition of either alien fibers or hazardous nanoparticles. Recycling of durable hydrocarbons is far superior to biodegradation. The facile thermal degradation enables liquefaction and quantitative recovery of low molar mass hydrocarbon oil and gas. Teamed up with biomass-to-liquid and carbon dioxide-to-fuel conversions, powered by renewable energy, waste hydrocarbons serve as renewable hydrocarbon feedstocks for the synthesis of high molar mass hydrocarbon materials. Herein, an overview is given on how innovations in catalyst and process technology enable tailoring of advanced recyclable hydrocarbon materials meeting the needs of sustainable development and a circular economy.