An Unconventional Route for Synthesis and Solid-State Processing of Low-Entangled Ultra-High Molecular Weight Isotactic Polypropylene

Introducing the reverse micelle formation during polymerization, and thus avoiding the catalyst support, aggregated single crystals of ultra-high molecular weight isotactic polypropylene having spherical morphology are obtained. The ease in flowability of the spherical nascent morphology, having a low-entangled state in the non-crystalline region of the single crystals in the semi-crystalline polymer, allows the sintering of the nascent polymer in the solid state without melting. Thus maintains a low-entangled state, and facilitates the translation of macroscopic forces to macromolecular length scale, without melting, leading to the formation of uniaxially drawn objects having unprecedented properties that can be used in the development of one component, high-performance, easy-to-recycle composites. Thus having the potential of replacing difficult-to-recycle hybrid composites.