Ethylene‐octene copolymers prepared by Dow's INSITE™ constrained geometry catalyst technology present a broad range of solid‐state structures from highly crystalline, lamellar morphologies to the granular morphology of low crystallinity copolymers. As the comonomer content increases, the accompanying tensile behavior changes from necking and cold drawing typical of a semicrystalline thermoplastic to uniform drawing and high recovery characteristic of an elastomer. Although changes in morphological features and tensile properties occur gradually with increasing comonomer content, the combined body of observations from melting behavior, morphology, dynamic mechanical response, yielding, and large‐scale deformation suggest a classification scheme with four distinct categories. Materials with densities higher than 0.93 g/cc, type IV, exhibit a lamellar morphology with well‐developed spherulitic superstructure. Type III polymers with densities between 0.93 and 0.91 g/cc have thinner lamellae and smaller spherulites. Type II materials with densities between 0.91 and 0.89 g/cc have a mixed morphology of small lamellae and bundled crystals. These materials can form very small spherulites. Type I copolymers with densities less than 0.89 g/cc have no lamellae or spherulites. Fringed micellar or bundled crystals are inferred from the low degree of crystallinity, the low melting temperature, and the granular, nonlamellar morphology. © 1996 John Wiley & Sons, Inc.

Studies of the crystallization, melting, and morphology of random ethylene/1-octene copolymers by a combination of differential scanning calorimetry and atomic force microscopy are presented. Two different crystallization mechanisms prevalent in separate temperature ranges are inferred from the effect of cooling rate on the temperature dependence of crystallinity, from the reversibility of crystallization/melting phenomena at the lowest temperatures, and from the temperature dependence of kinetic parameters describing isothermal crystallization and melting. Morphological studies of these copolymers demonstrate the coexistence of two distinct crystalline superstructures (i.e., lamellae and fringed-micellar or chain cluster structures) which we tentatively associate with the two crystallization mechanisms. The multiple melting behavior of these copolymers is associated with the existence of separate morphological entities and is not explained by a mechanism of melting−recrystallization−remelting. Finally, the upward shift of the melting endotherm of secondary crystals (i.e., these formed by the low-temperature mechanism) with longer crystallization times is explained by a decrease in the molar conformational entropy of the remaining amorphous fraction as a result of secondary crystallization.

Exciting new developments in polyolefin synthesis give rise to olefinic block copolymers with properties typical of thermoplastic elastomers. The blocky copolymers synthesized by chain shuttling technology consist of crystallizable ethylene-octene blocks with low comonomer content and high melting temperature (hard blocks), alternating with amorphous ethylene-octene blocks with high comonomer content and low glass transition temperature (soft blocks). This paper describes the materials science of these unique polymers as characterized by thermal analysis, X-ray diffraction, microscopy, and tensile deformation. The crystallizable nature of the hard block and the crystalline morphologies are consistent with an average hard block length that is well in excess of 200 carbon atoms. The crystallizable blocks are long enough to form well-organized lamellar crystals with the orthorhombic unit cell and high melting temperature. The lamellae are organized into space-filling spherulites in all compositions even in copolymers with only 18 wt % hard block. The morphology is consistent with crystallization from a miscible melt. Crystallization of the hard blocks forces segregation of the noncrystallizable soft blocks into the interlamellar regions. Good separation of hard and soft blocks in the solid state is confirmed by distinct and separate β-and R-relaxations in all the blocky copolymers. Compared to statistical ethylene-octene copolymers, the blocky architecture imparts a substantially higher crystallization temperature, a higher melting temperature and a better organized crystalline morphology, while maintaining a lower glass transition temperature. The differences between blocky and statistical copolymers become progressively more apparent as the total comonomer content increases.