A temperature window of extrudability and reduced flow resistance in high-molecular weight polyethylene; interpretation in terms of flow-induced mobile hexagonal phase

An unexpected feature of melt flow behavior has been identified in high‐molecular weight (≥ 4.105) polyethylenes such as are being considered unprocessable at conventional temperatures (> 160°C) and at practicable extrusion rates (> 1 cm/min). In addition to a lower temperature window of smooth extrudability, lying in the range of 138–155°C already observed in previous works, we now discovered within this window a narrow temperature interval (150–152°C) of minimum flow resistance (viscosity). The new effect has the attributes of being associated with a new phase of increased fluidity. This, in turn, we attribute to a transient mesophase arising through the chain‐orienting effect of the elongational flow within the extrusion orifice; from the experiments presented here, this mesophase depends critically on both molecular weight and strain rate. The hexagonal form of polyethylene, known to exist under other circumstances, is suggested as this mesophase. The relevance of the new findings for applications (extrusion, melt rheology) and for fundamentals (orientation‐induced phase transformations, liquid crystals from flexible chains in particular) should be obvious and are accordingly highlighted.