Morphological Distribution in Micro-Injected Polypropylene Parts in the Presence of β-Nucleating Agent

Abstract

Micro-injection molding is attracting much attention nowadays. Characterization of the morphological distribution in parts prepared by micro-injection molding is thus of growing importance. The morphological features of micro-parts may strongly differ from those of the macro-parts prepared by conventional injection molding, resulting in specific physical properties. In the present study, β-nucleated isotactic polypropylene micro-parts (μPPB) with 200 μm thickness, as well as macro-parts (PPB) with 2000 μm thickness, were prepared. Polarized light microscopy (PLM), scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and wide-angle X-ray diffraction (WAXD) were used to investigate their morphological features. The results show that the morphology distribution in μPPB had many differences from that of the PPB. The one-dimensional WAXD and DSC analysis showed similar results; the degree of crystallinity of the μPPB was higher than that of the PPB. However, the content of β-crystals of μPPB was lower than that of the PPB. This can be explained by the restraining effect for the formation of β-crystals in β-nucleated isotactic polypropylene (iPP) under the strong shear field. The through-the thickness-morphology of both μPPB and PPB exhibited a “skin-core” structure from PLM observations, but the former had a large fraction of shear layer in comparison to the latter implied. The SEM observations showed that the shear layer of μPPB consisted of a highly oriented shish-kebab structure, while that of the core layer consisted of deformed spherulites structure. The two-dimensional WAXD pattern of the core layer of PPB, showing full Debye rings, indicated an overall random orientation of the iPP chains, while the arcing indicated a pronounced orientation in the shear layer. The more pronounced arcing of the μPPB indicated a more pronounced orientation.

Keywords:

• micro-injection molding
• morphological distribution
• orientation
• polypropylene
• shish-kebab
• skin-core structure
• β-nucleating agent

Acknowledgments

We would like to express our great thanks to the National Natural Science Foundation of China (50873072, 51010004) and the Sichuan Science and Technology Support Project (2011FZ0033). We are indebted to the National Synchrotron Radiation Laboratory (NSRL) in the University of Science and Technology of China and Guoqiang Pan (NSRL) for his help in the synchrotron WAXD experiment.