Polymer Solidification under Pressure and High Cooling Rates

Polymer solidification under processing conditions is a complex phenomenon in which the kinetics of flow, high thermal gradients and high pressures determine the product morphology. The study of polymer structure formed under pressure has been mainly made using conventional techniques such as dilatometry and differential scanning calorimetry under isothermal conditions or non isothermal conditions but at cooling rates several orders of magnitude lower than those experienced in industrial processes. A new equipment has been recently developed and improved to study the crystallization of polypropylene when subjected to pressure and cooled rapidly. An experimental apparatus essentially constituted of a special injection mould has been employed. Polymer samples can be cooled at a known cooling rate and under a known pressure. Micro Hardness (MH), Wide angle x-ray diffraction (WAXD), Polarised Optical Microscopy (POM) and density measurements are then used to characterize the sample morphology. The results of rapid cooling experiments under pressure on an iPP sample display a lower density and a lower density dependence on cooling rate for increasing pressure. Micro hardness confirms the trend.

A deconvolution technique of WAXD patterns is used to evaluate the final phase content of samples and to assess a crystallization kinetics behaviour. Phase distribution results indicate that the decrease of alpha phase with pressure is balanced by an increase of the mesomorphic phase leaving unaffected the amorphous phase content. This peculiar behaviour can be easily related to a negative influence of pressure on the kinetics of the crystallization of alpha phase.

Solidification Behaviour of PA6/iPP Blends at High Cooling Rates

The non isothermal crystallization behaviour of two model blends of immiscible polymers (an isotactic polypropylene and a polyamide-6) was examined by a quenching procedure within a range of cooling rates from 0.1 to above 1000°C/s in order to emulate the solidification conditions arising during polymer processing. The final structure of the blends was analyzed by density and WAXD and the transition from stable to metastable phases in the blends and the pure homopolymers was compared examining their dependence on cooling rate. This shows that crystallization in the blends is always faster since the transitions move to larger cooling rates. Observation of morphological details suggests that this can be due to enhanced nucleation at the interface. The density variation in the case of the polyamide-6 rich blend is larger than expected from an additive volume contribution which may be ascribed to development of microvoids at the interface. In the case of the isotactic polypropylene rich blend the additive volume contribution is consistent with experimental observations.

Injection Molding of iPP

An experimental study of iPP injection molding is carried out. Pressure distribution during both filling and post filling stages, mass entering the mold during each stage of the process, morphology and crystallinity distribution of the final object are analysed. Interesting features are evidenced and discussed in relation to gate geometry and filling flow rate. Evidence of flow crystallization inside the cavity is also reported.

Polymeric scaffolds prepared via thermally induced phase separation: tuning of structure and morphology

Scaffolds suitable for tissue engineering applications like dermal reconstruction were prepared by Thermally Induced Phase Separation (TIPS) starting from a ternary solution PLLA/dioxane/water. The experimental protocol consisted of three consecutive steps, a first quench from the homogeneous solution to an appropriate demixing temperature (within the metastable region), a holding stage for a given residence time, and a final quench from the demixing temperature to a low temperature (within the unstable region). A large variety of morphologies, in terms of average pore size and interconnection, were obtained upon modifying the demixing time and temperature, owing to the interplay of nucleation and growth processes during the residence in the metastable state. An interesting combination of micro and macroporosity was observed for long residence times in the metastable state (above 30 min at 35 degrees C). Preliminary degradation tests in a biological mimicking fluid (D-MEM with bovine serum) showed a significant weight loss during the initial stages (ca. 30% in 30 days) related to the degradation of the amorphous part, followed by a negligible weight loss in the next days (few percent from 30 to 60 days).