Lamellar morphology of random metallocene propylene copolymers studied by atomic force microscopy

Four sets of propylene based random copolymers with co-units of ethylene, 1-butene, 1-hexene and 1-octene, and a total defect content up to ∼9 mol% (including co-unit and other defects), were studied after rapid and isothermal crystallization. Etched film surfaces and ultramicrotomed plaques were imaged so as to enhance contrast and minimize catalyst and co-catalyst residues. While increasing concentration of structural irregularities breaks down spherulitic habits, the formation of the gamma polymorph has a profound effect on the lamellar morphology. Lamellae grown in the radial axis of the spherulite and branches hereon are replaced in γ-rich copolymers with a dense array of short lamellae transverse or tilted to the main structural growth axis. This is the expected orientation for γ iPP branching from α seeds. Spherulites are formed in copolymers with non-crystallizable units (1-hexene and 1-octene) up to ∼3 mol% total defect content and were observed up to ∼6 mol% in those with partially crystallizable comonomers (ethylene and 1-butene). However, lamellae were observed in all the copolymers analyzed, even in the most defective ones, highlighting the important role of the gamma polymorph in propagating lamellar crystallites in poly(propylenes) with a high concentration of defects. Long periods measured from AFM and SAXS are comparatively analyzed.