Morphology of polypropylene/poly(ethylene-co-propylene) in-reactor alloys prepared by multi-stage sequential polymerization and two-stage polymerization

The morphology of two polypropylene/poly(ethylene-co-propylene) (PP/EPR) in-reactor alloys prepared by multi-stage sequential polymerization (MSSP) and two-stage polymerization (TSP) processes, respectively, was investigated. It is observed that the alloy prepared by MSSP (sample 1) exhibits lower phase separation temperature than the alloy prepared by TSP (sample 2), probably due to the higher content of PP segments in the blocky copolymer fractions of sample 1. Two thermal treatments were applied to the samples: (1) The samples were directly quenched from 230 °C to 132 °C for isothermal crystallization; (2) The samples were firstly held at 160 °C for 60 min for phase separation and then cooled to 132 °C for crystallization. It is found that both microstructure and thermal treatment affect the morphology of the alloys, and the differences in morphology are interpreted in terms of phase diagram. For sample 1 and for the samples subjected to phase separation prior to crystallization, the EPR-rich phase contains more PP and thus is more viscous, which leads to more inclusion of the EPR-rich phase into the spherulites. A coarse spherulitic structure is formed due to crystallization of PP in the included EPR-rich phase. More included EPR-rich phase and its stronger crystallizability can further lead to the narrower boundaries and formation of connections between the adjacent spherulites.