In situ tailoring the hierarchical microstructures in polyethylene films fabricated by thermally induced phase separation via temperature gradient fields

In this study, a series of polyethylene thin films were prepared by thermally induced phase separation (TIPS) method with di(2-ethylhexyl)phthalate as the diluent. Morphological observations showed that the microstructures at different locations were fairly distinct and could generally be divided into three layers. When the polymer concentration was lower than the monotectic point (Φm), both pore size and porosity in TIPS films were heavily determined by growth time and growth rate of the diluent droplets. At relatively higher polymer concentration, cooling rate heavily affected the pore size in the films primarily through its influence on polymers’ crystallization process. The relationship between the film microstructure and cooling rate was quantitatively investigated (especially the effect of quenching conditions on the evolution of film morphology) with the aid of an enthalpy transformation method, which established the three-dimensional temperature profiles and supplied an insight into the competition between phase separation kinetics and polymer crystallization. In addition, our findings showed that the pore size, porosity and thermal stability of films all increased with an increasing quenching temperature, which was significantly different from the trends of variation in water vapor transmission rate as well as the $$ E^\prime_{ \hbox{max} } $$ and $$ E^\prime\prime_{ \hbox{max} } $$ values of dynamic mechanical analysis as the quenching temperature increased. The present work presents a facile way of in situ tailoring hierarchical microstructures in TIPS films of crystalline polymers, which will be very useful to the design of polymer porous films with specific properties.