Microstructure, morphology, crystallization and rheological behavior of impact polypropylene copolymer

Impact polypropylene copolymer (IPC), named polypropylene catalloy, not only possesses excellent impact property, but also presents good rigidity. Its superior performances result from the complicated composition and microstructure. In the present article, recent progress in the studies on microstructure, morphology, crystallization and rheological behavior of IPC is summarized, and findings of the authors and their collaborators are reported. In general, IPC is divided into three components, i.e., ethylene-propylene random copolymer (EPR), a series of different segment lengths ethylene-propylene copolymer (EbP) and propylene homopolymer. The reasonable macromolecular structures of EbP and a multilayered core-shell model of dispersed phase structure in IPC were proposed, in which the dispersed phase consists of an outer EbP shell, an inner EPR layer and an EbP core. It is found that the annealing at melt-state may lead to an abnormal phase inversion, and the phase inversion disappears when temperature cools down to room temperature. The cause of phase inversion is ascribed to the existence of EbP component, which results in the stronger activity of the dispersed phase. The crystalline structure and morphologic results confirm the formation of beta-iPP in IPC. Furthermore, it is found that the ethylene content in IPC and cooling rate of the samples have an important influence on the formation of beta-iPP. Based on the crystallization kinetics analyzed by Lauritzen-Hoffman theory, crystallization behavior of different IPC samples is discussed and it is proposed that the dilution effect of ethylene-propylene copolymer has a more remarkable influence on surface nucleation than on crystal growth. In addition, annealing at high temperature can result in the changes of chain structure for IPC, and this instability is ascribed to the oxidative degradation and crosslink reaction mainly in iPP component.