Crystal Nucleation in Glassy Poly(l-lactic acid)

Crystallization of Poly(ethylene terephthalate): A Review

Poly(ethylene terephthalate) (PET) is a thermoplastic polyester with excellent thermal and mechanical properties, widely used in a variety of industrial fields. It is a semicrystalline polymer, and most of the industrial success of PET derives from its easily tunable crystallization kinetics, which allow users to produce the polymer with a high crystal fraction for applications that demand high thermomechanical resistance and barrier properties, or a fully amorphous polymer when high transparency of the product is needed. The main properties of the polymer are presented and discussed in this contribution, together with the literature data on the crystal structure and morphology of PET. This is followed by an in-depth analysis of its crystallization kinetics, including both primary crystal nucleation and crystal growth, as well as secondary crystallization. The effect of molar mass, catalyst residues, chain composition, and thermo-mechanical treatments on the crystallization kinetics, structure, and morphology of PET are also reviewed in this contribution.

A Relatively Simple Look at the Rather Complex Crystallization Kinetics of PLLA

This work demonstrates that, despite the existence of a significant number of works on PLA crystallization, there is still a relatively simple way, different from those already described, in which its complex kinetics can be observed. The X-ray diffraction (XRD) results presented here confirm that the PLLA under study crystallizes mostly in the α and α' forms. An interesting observation is that at any temperature in the studied range of the patterns, the X-ray reflections stabilize with a given shape and at a given angle, different for each temperature. That means that both α and α' forms coexist and are stable at the same temperatures so that the shape of each pattern results from both structures. However, the patterns obtained at each temperature are different because the predominance of one crystal form over the other depends on temperature. Thus, a two-component kinetic model is proposed to account for both crystal forms. The method involves the deconvolution of the exothermic DSC peaks using two logistic derivative functions. The existence of the rigid amorphous fraction (RAF) in addition to the two crystal forms increases the complexity of the whole crystallization process. However, the results presented here show that a two-component kinetic model can reproduce the overall crystallization process fairly well over a broad range of temperatures. The method used here for PLLA may be useful for describing the isothermal crystallization processes of other polymers.

Young's modulus of the different crystalline phases of poly (l-lactic acid)

Young's modulus of α'- and α-crystals of poly (l-lactic acid) (PLLA), more precisely, of aggregates of isotropically arranged lamellae, has been estimated based on dynamic-mechanical analysis of sets of isotropic film samples containing largely different though well-defined amounts of crystals. Evaluation of the modulus of elasticity of these film samples yielded the dependence of Young's modulus as a function of the enthalpy-based crystallinity, increasing with the crystal fraction in the assessed range, from zero to about 75% crystallinity. Extrapolation towards 100% crystallinity suggests values of Young's modulus of around 3.7 and 4.6 GPa for isotropic aggregates of α'- and α-crystals, respectively, being only slightly higher than the modulus of the unaged glassy amorphous phase of 3.0 GPa. Noting the inherent anisotropy of the crystal modulus, suggested in the literature, the average modulus determined in this work seems to be controlled by weaker interchain secondary bonding but not the modulus in chain direction. Great effort has been undertaken to minimize errors by keeping the lamellar thickness in samples of different crystallinity constant, and by providing evidence for independence of the moduli on the spherulitic superstructure.

Polymer Chains Fold Prior to Crystallization

There are long-standing debates in crystallization mechanism of polymer chains at the molecular levels: Which comes first, chain folding or lamellae formation during crystallization? In this study, we report the local chain trajectory of ¹³C-labeled semicrystalline polymer in an extreme case of rapidly quenched glassy state as well as thermodynamically stable crystals formed via different pathways from glass and melt. Magnetically dipole interactions do not require a long-range order of molecular objects and thus enable us to trace the local chain trajectory of polymer chains even in a glassy state. To accurately characterize the local chain trajectory of polymer glass, the natural abundance effect on ¹³C-¹³C double-quantum (DQ) nuclear magnetic resonance (NMR) signal is re-examined using extended chain conformation. As results, it is found that glassy chains adopt the same adjacent re-entry structure (adjacent re-entry number, n = 1) with the melt- and cold-grown crystals. From these results, it is concluded that (i) folding occurs prior to crystallization and (ii) melt and cold crystallization do not induce additional folding but proceed with rearrangements of polymer chains in the existing templates.

Temperature and Thickness Dependence of the Time Scale of Crystallization of Polymers under 1D Confinement

Confined in nanodomains, polymers crystallize much slower than in bulk due to both finite size and interfacial effects. These two factors are successfully disentangled in our phenomenological framework, which provides a measurement of the time scale of crystallization via a product of probabilities involving nucleation and of chain diffusion. In this Letter, we demonstrate that our model allows determining the Gibbs free energy of the formation of a critical size nucleus indicated by the classical nucleation theory for bulk polymer melts. In addition to that, by means of segmental mobility data and one single set of isothermal crystallization measurements at different confinement degrees, our model predicts the right temperature and thickness dependence of the crystallization time.

Stability of Crystal Nuclei of Poly (butylene isophthalate) Formed Near the Glass Transition Temperature

Tammann’s two-stage crystal-nuclei-development method is applied for analysis of the thermal stability of homogenously formed crystal nuclei of poly(butylene isophthalate) (PBI) as well as their possible reorganization on transferring them to the growth temperature, using fast scanning chip calorimetry. Crystal nuclei were formed at 50 °C, that is, at a temperature only slightly higher than the glass transition temperature, and developed to crystals within a pre-defined time at the growth temperature of 85 °C. The number of nuclei, overcritical at the growth temperature, was detected as a function of the transfer-conditions (maximum temperature, heating rate) by evaluation of the developed crystal fraction. For different size-distributions of crystal nuclei, as controlled by the nucleation time, there is detected distinct reduction of the nuclei number on heating to maximum temperatures higher than about 90 to 110 °C, with the latter value holding for longer nucleation time. Longer nucleation allows for both increasing the absolute nuclei number and generation of an increased fraction of larger nuclei. Heating at 1000 K/s to 140–150 °C causes “melting” of even the most stable nuclei. While direct transfer of crystal nuclei from the nucleation temperature (50 °C) to the growth temperature (85 °C) reveals negligible effect of the transfer-heating rate, in-between heating to higher temperatures is connected with distinct nuclei-reorganization above 85 °C on heating slower than 1000–10.000 K/s. The performed study not only provides specific valuable information about the thermal characteristics of crystal nuclei of PBI but also highlights the importance of proper design of Tammann’s nuclei development experiment for analysis of nuclei numbers. With the evaluation of critical rates of temperature-change for suppression of non-isothermal formation of both nuclei and crystals, the kinetics of crystallization of the slow crystallizing PBI is further quantified.

Distinct dynamics of structural relaxation in the amorphous phase of poly(l-lactic acid) revealed by quiescent crystallization

Fast scanning calorimetry (FSC) experiments were performed to investigate physical aging in amorphous and semi-crystalline poly(l-lactic acid)s (PLLAs) that were thermally crystallized under conditions leading to the α'- or α-crystalline form, and either favouring or inhibiting the development of a rigid amorphous fraction (RAF). The enthalpy of recovery was calculated after two procedures of rescaling to the content of the whole amorphous phase and also to the only content of the mobile amorphous fraction (MAF), which helped in clarifying the contribution of the RAF. From the dependence of the structural relaxation rate on the aging temperature, two regimes were evidenced for all samples. In the aging temperature domain situated close to the glass transition, the structural relaxation occurs significantly faster in the MAF. Its rate is independent of the aging temperature and is not influenced by the microstructure. However, the distance to equilibrium is higher in samples for which the coupling is strong between crystal and amorphous, implying that the time to reach equilibrium is also higher. In contrast, at low aging temperatures, for which the whole amorphous phase can be considered as solid, MAF and RAF exhibit the same structrural relaxation rate. This convergence in the relaxation kinetics by decreasing the temperature of physical aging was interpreted as the evolution of relaxation dynamics in the MAF from segmental to local. This change is highlighted by the comparison between MAF and RAF relaxation kinetics, but it occurs similarly in a pure amorphous system.

Enthalpy Relaxation, Crystal Nucleation and Crystal Growth of Biobased Poly(butylene Isophthalate)

The crystallization behavior of fully biobased poly(butylene isophthalate) (PBI) has been investigated using calorimetric and microscopic techniques. PBI is an extremely slow crystallizing polymer that leads, after melt-crystallization, to the formation of lamellar crystals and rather large spherulites, due to the low nuclei density. Based upon quantitative analysis of the crystal-nucleation behavior at low temperatures near the glass transition, using Tammann's two-stage nuclei development method, a nucleation pathway for an acceleration of the crystallization process and for tailoring the semicrystalline morphology is provided. Low-temperature annealing close to the glass transition temperature (T_g) leads to the formation of crystal nuclei, which grow to crystals at higher temperatures, and yield a much finer spherulitic superstructure, as obtained after direct melt-crystallization. Similarly to other slowly crystallizing polymers like poly(ethylene terephthalate) or poly(l-lactic acid), low-temperature crystal-nuclei formation at a timescale of hours/days is still too slow to allow non-spherulitic crystallization. The interplay between glass relaxation and crystal nucleation at temperatures slightly below T_g is discussed.

Controlling Nucleation in Quasi-Two-Dimensional Langmuir Poly(l-lactide) Films through Variation of the Rate of Compression

We studied morphological changes in a quasi-two-dimensional Langmuir film of low molar mass poly(l-lactide) upon increasing the surface density, starting from randomly distributed molecules to a homogeneous monolayer of closely packed molecules, followed by nucleation and growth of mesoscopic, three-dimensional clusters from an overcompressed monolayer. The corresponding nucleation density of mesoscopic clusters within the monolayer can be tailored through variation of the rate of compression. For a given surface density and temperature, the nucleation probability was found to increase linearly with the rate of compression, allowing to adjust the density of mesoscopic clusters over nearly 2 orders of magnitude.

Rapid crystallization and mesophase formation of poly(L-lactic acid) during precipitation from a solution

Very rapid crystallization behaviors of poly(L-lactic acid) (PLLA) are observed at room temperature when it is precipitated from a chloroform solution into a large amount of alcohols (non-solvents). The resulting crystalline phase contains both a highly ordered (α) and less ordered (α′) modifications, and the fraction of these phases depends on the alcohols used as the non-solvents: methanol tends to produce the highly ordered phase. The degree of crystallinity tends to be high for lower alcohols. When the precipitation occurs in n-hexane, almost no crystalline phase is formed, but a mesomorphic phase is formed as a precursor to the crystalline phase. The results suggest that the hydroxyl group of alcohols tends to promote the crystallization of PLLA. However, it is found that the precipitation in methanol at lower temperatures, such as 0°C, does not yield any crystalline phase. It is suggested that the present rapid crystallization during precipitation originates from the enhanced mobility of PLLA molecules in a metastable (non-equilibrium) liquid state.

Processing of PVDF-based electroactive/ferroelectric films: importance of PMMA and cooling rate from the melt state on the crystallization of PVDF beta-crystals

Poly(vinylidene difluoride) (PVDF) displays attractive ferroelectric/piezoelectric properties and its polar β-crystals are specifically targeted for achieving electroactive applications. However, their direct crystallization from the melt state represents a challenging task that has never been addressed using melt-state processes. The use of poly(methyl methacrylate) (PMMA) is herein investigated to promote the PVDF polar β-phase using melt-blending and extrusion-calendering technologies. The presence of the β-phase is here confirmed by ATR-FTIR and WAXS experiments with blends at a PMMA content as low as 5 wt%. The key role of PMMA for the β-phase crystallization from the melt state was unambiguously highlighted with the help of Flash DSC experiments in non-isothermal cooling mode from the melt state. PMMA is able to efficiently shift the α-to-β crystal transition to lower cooling rates (>100-200 °C s-1), making the achievement of the PVDF polar β-phase for these blends compatible with conventional processing tools. A crystal phase diagram is proposed for the PVDF/PMMA blends to highlight the dual effects of both PMMA and cooling rate on the PVDF crystallization during melt-processing. Ferroelectric properties were even observed for the blends containing PMMA up to 10 wt% with the highest remanent polarization obtained at 5 wt% PMMA. After 10 wt% PMMA, a progressive transition from ferroelectric to pseudo-linear dielectric behavior is observed more likely due to the presence of PMMA in the interlamellar amorphous phase of the polar PVDF spherulites as shown by SAXS experiments. In this work, we successfully demonstrated that PMMA plays a key role in the crystallization of PVDF polar crystals from the melt state, enabling large-scale and continuous extrusion processing of PVDF-based materials with attractive dielectric properties for sensing and harvesting applications.

PLA Melt Stabilization by High-Surface-Area Graphite and Carbon Black

Small amounts of carbon nanofillers, specifically high-surface-area graphite (HSAG) and more effectively carbon black (CB), are able to solve the well-known problem of degradation (molecular weight reduction) during melt processing, for the most relevant biodegradable polymer, namely poly(lactic acid), PLA. This behavior is shown by rheological measurements (melt viscosity during extrusion experiments and time sweep-complex viscosity) combined with gel permeation chromatography (GPC) experiments. PLA's molecular weight, which is heavily reduced during melt extrusion of the neat polymer, can remain essentially unaltered by simple compounding with only 0.1 wt % of CB. At temperatures close to polymer melting by compounding with graphitic fillers, the observed stabilization of PLA melt could be rationalized by scavenging traces of water, which reduces hydrolysis of polyester bonds. Thermogravimetric analyses (TGA) indicate that the same carbon fillers, on the contrary, slightly destabilize PLA toward decomposition reactions, leading to the loss of volatile byproducts, which occur at temperatures higher than 300 °C, i.e., far from melt processing conditions.

Nucleation Enhancement in Stereodefective Poly(l-lactide) by Free Volume Expansion Resulting from Low-Temperature Pressure CO₂ Preconditioning

Nucleation enhancement in a highly stereodefective poly(l-lactide) (PLLA) with an optical purity of 88% by low-temperature pressure (0 and 35 °C under 2 MPa) CO₂ preconditioning was investigated using differential scanning calorimetry (DSC), infrared (IR) spectroscopy, polarized optical microscopy (POM) as well as positron annihilation lifetime spectroscopy (PALS). Despite the preconditioning of the melt-quenched films for 2 h, IR results indicated that no trace of mesophase was generated and the samples remained in the glassy state. However, judging from the results of DSC, IR, and POM, when compared to the untreated sample, both the treated ones showed a significantly enhanced crystal nucleation effect, resulting in the corresponding greatly enhanced crystallization kinetics. Moreover, owing to the existence of the retrograde vitrification, the conditions of the previous low-pressure CO₂ conditioning affected the nucleation enhancement effect. When compared to the case of 35 °C, the much lower temperature of 0 °C was more effective for nucleation enhancement. The PALS results indicated that the enlarged free volume, which resulted from the CO₂ conditioning, largely accounted for the formation of locally ordered structures, providing many more potential nucleation sites for forming critical nuclei and thus the resulting enhanced crystallization kinetics in glassy PLLA. The present results have implications in understanding the nucleation enhancement effect, in particular in stereodefective PLLA systems, which possess extremely low crystallization ability and are thus probably too problematic to be evaluated by conventional methods.

Homogeneous crystal nucleation in polymers

The pathway of crystal nucleation significantly influences the structure and properties of semi-crystalline polymers. Crystal nucleation is normally heterogeneous at low supercooling, and homogeneous at high supercooling, of the polymer melt. Homogeneous nucleation in bulk polymers has been, so far, hardly accessible experimentally, and was even doubted to occur at all. This topical review summarizes experimental findings on homogeneous crystal nucleation in polymers. Recently developed fast scanning calorimetry, with cooling and heating rates up to 10⁶ K s^-1, allows for detailed investigations of nucleation near and even below the glass transition temperature, including analysis of nuclei stability. As for other materials, the maximum homogeneous nucleation rate for polymers is located close to the glass transition temperature. In the experiments discussed here, it is shown that polymer nucleation is homogeneous at such temperatures. Homogeneous nucleation in polymers is discussed in the framework of the classical nucleation theory. The majority of our observations are consistent with the theory. The discrepancies may guide further research, particularly experiments to progress theoretical development. Progress in the understanding of homogeneous nucleation is much needed, since most of the modelling approaches dealing with polymer crystallization exclusively consider homogeneous nucleation. This is also the basis for advancing theoretical approaches to the much more complex phenomena governing heterogeneous nucleation.