Novel method for fabrication of PP/HDPE/PP trilayer microporous membrane with a highly orientated structure

Abstract

In this work, a highly orientated polopropelene/high-density polyethylene/polopropelene (PP/HDPE/PP) trilayer cast film was obtained from viscous encapsulation of HDPE and PP which involved of controlling the molecular factors and processing conditions. Consequently, a stable stratified flow was obtained as a result of phase-segregation through a single screw extruder under a high draw ratio (DR). Microporous HDPE, PP monolayer films as well as PP/HDPE/PP trilayer film have been successfully fabricated after a proper cold and hot stretching. The influence of DR and annealing process on crystalline structure and orientation of monolayer and trilayer membrane was investigated by differential scanning calorimetry, two-dimensional wide-angle X-ray diffraction and Fourier transform infrared. Both crystallinity and crystalline orientation increased with DR and annealing process. Additionally, the crystallinity in PP/HDPE/PP was lower than it in monolayer films but the orientation of PP/HDPE/PP was higher compared to monolayer films. The lamellae structure of HDPE, PP, and PP/HDPE/PP cast films prepared at different DR values and the influence of annealing process was also studied. The lamellae parameters, the long period (L p ), the thickness of crystalline region (L c ) and the thickness of amorphous region (L a ) were obtained via 2D-small angle X-ray scattering. The long period (L p ) of PP was 35% smaller than HDPE implying tight stacking in PP. The scanning electron microscopy micrographs of the membrane surface morphology and cross-section obtained from the cold and hot stretching of 30% and 150%, respectively. The results showed that the pore size of HDPE was greater than PP. Besides, the pore number and regularity of PP/HDPE/PP at DR = 90, which had a porosity of 0.48, was the best among all samples. The crosssection of PP/HDPE/PP trilayer membrane was found to be a multilayer structure. However, the majority of HDPE phase was in the middle of film while PP phase was absolutely at the edge of the film. The current work may open an entirely novel and simple way to fabricate PP/HDPE/PP trilayer microporous films.