Heat Transfer and Crystallization Dynamics in Polymer Processing

Polymer processing encompasses a range of techniques such as injection moulding, extrusion and blow moulding, in which the precise control of heat transfer and crystallisation dictates the final microstructure and performance of manufactured parts. Heat transfer at the polymer–mould interface governs cooling rates, which in turn determine the phase transitions from molten to semi-crystalline or amorphous solid. The interplay between thermal conductivity, interface resistance and melt flow influences temperature gradients that drive nucleation and growth of crystalline domains, such as spherulites, within semi-crystalline polymers. Rapid mould cooling can lead to incomplete crystallisation, altering mechanical strength, dimensional stability and optical clarity, whereas slower cooling may yield higher degrees of crystallinity but risks warpage and cycle time penalties. Advances in experimental characterisation have improved the quantification of interfacial heat transfer coefficients and thermal contact resistance, while computational models now integrate pressure–volume–temperature (pVT) data with crystallisation kinetics theories to predict morphology evolution under non-isothermal conditions. Molecular dynamics simulations have shed light on micro- and nanoscale phenomena including wall slip effects and their impact on interface thermal resistance. Together, these insights inform the optimisation of processing parameters, enabling the tailoring of polymer properties for applications spanning from microfluidic devices to structural components.

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Heat Transfer and Crystallization Dynamics in Polymer Processing publication trend

The graph below shows the total number of articles in heat transfer and crystallization dynamics in polymer processing across all publications each year (not limited to Nature Index journals).

Technical terms

Heat transfer coefficient (HTC): The proportionality constant describing heat flux across the polymer–mould interface per unit temperature difference.

Thermal contact resistance (TCR): The resistance to heat flow at the interface between two solids, arising from microscopic gaps and imperfect contact.

Cooling rate: The rate at which temperature decreases during processing, typically expressed in degrees per second, affecting crystallisation and morphology.

Crystallisation kinetics: The mathematical description of nucleation and growth rates of crystalline structures within polymers under non-isothermal conditions.

Pressure–volume–temperature (pVT) behaviour: The relationship describing changes in specific volume of a polymer as a function of pressure and temperature, fundamental to process simulation.

References

1. Precision injection moulding of micro components: Determination of heat transfer coefficient and precision process simulation. International Journal of Mechanical Sciences (2024).
2. Meta‐analysis of thermal contact resistance in injection molding: A comprehensive literature review and multivariate modeling. Polymer Engineering & Science (2023).
3. Wall Slip Behaviour of Polymers Based on Molecular Dynamics at the Micro/Nanoscale and Its Effect on Interface Thermal Resistance. Polymers (2020).
4. Non-Isothermal Crystallisation Kinetics of Polypropylene at High Cooling Rates and Comparison to the Continuous Two-Domain pvT Model. Polymers (2020).