This work presents an in-depth study
of fiber-induced nucleation
and crystalline morphology in polybutene-1/single-fiber composites.
The nucleation ability of various fibers, including carbon, glass,
polypropylene (PP), poly(l-lactide) (PLLA), and stereocomplex
(SC)-poly(lactide), is investigated via polarized optical microscopy.
A polybutene-1 (PB-1) fiber made of the trigonal Form I polymorph
is also adopted in an all-PB-1 composite. Two different types of morphologies
of PB-1 Form II developed on the surface of the different fibers during
isothermal crystallization. They are a transcrystalline layer (TCL)
on the Form I fiber only and a hybrid shish–calabash (HSC)
on all of the other fibers. Upon nonisothermal crystallization, a
transition from the HSC to TCL morphology for the sole PP fiber is
found. Quantitative studies of nucleation kinetics showed that the
lowest nucleation free-energy barrier is exhibited by the PB-1 Form
I fiber, due to the occurrence of cross-nucleation with Form II, possibly
via epitaxial matching. On the other hand, the highest nucleation
energy barrier is that of the PP fiber, despite the very similar chemical
constitution. Moreover, a large variation in the pre-exponential factor
of the nucleation rate among the various fibers suggests major differences
in the available nucleation sites per unit area. The number of such
sites is found to inversely correlate with surface roughness and,
for the first time, is used to understand the obtainable morphology.
In fact, we show that, notwithstanding the height of the free-energy
barrier for nucleation, TCL can only be obtained when a sufficiently
high number of nucleation sites are provided.