Polypropylene Blends Research Articles

Morphological analysis of mechanically recycled blends of high density polyethylene and polypropylene with strong difference in melt flow index

Polyolefin (PO) blends are difficult to separate due to density and chemical structure similarities. The associated waste treatment in the context of mechanical recycling is therefore complicated by the establishment of multi-phase morphologies that are not yet fully understood. In the present work, a high density polyethylene (HDPE) with a very high melt flow index (MFI) and a polypropylene (PP) with a very low MFI are deliberately mingled to better understand the full spectrum of morphological variations for PO blending. The linkage with the control over injection mold-based mechanical properties such as tensile strength, elasticity modulus, elongation at break, and impact strength is made. This is done supported by the connecting of experimental analyses at different scales, including (i) the molecular scale via size exclusion chromatography and Fourier transform infrared spectroscopy (FTIR), and (ii) the meso-scale via scanning electron and polarized light microscopy as well as differential scanning calorimetry, including a differentiation between the bulk and surface region. Emphasis is both on blends processed once and re-processed either once, twice or three times. For the single processing, it is demonstrated that in most cases a droplet morphology is obtained, with smaller droplets in case HDPE is the minor component and with a dominance of HDPE at the surface even for 60% PP, due to a better HDPE flowability. It is further shown that the scission of PP chains and crosslinking of HDPE chains respectively facilitates and inhibits crystallization, at least if meso-scale -mixing as more evident during re-processing is not taking over. It is also highlighted that the properties of PP can be enhanced by adding up to 10 wt% HDPE, acting as a filler, and that the (ideally) reprocessed blends remain suitable for application.

Investigating the effect of compatibilizers on environmental stress cracking resistance in polypropylene/low density polyethylene blends

The present study focuses on the effect of octylphenoxy poly(ethyleneoxy)ethanol (IGEPAL CA 630) on the environmental stress cracking resistance (ESCR) of blends of polypropylene (PP) and low-density polyethylene (LDPE) at different weight fractions without and with the addition of two compatibilizers, corresponding to styrene-ethylene-butylene-styrene (SEBS) copolymer and styrene-ethylene-butylene maleate (SEBS-g-MA). Compression molding was used after mixing the melt in a Brabender internal mixer to create the blends. ESCR of the blends was determined by exposing the blends to a solution of IGEPAL CA 630 the presence of stress. Mechanical (tensile) and thermal properties are extracted to evaluate the effect of adding the compatibilizers SEBS and SEBS-g-MA to the blend. In the environmental stress cracking (ESCR) tests, the time to failure increases with increasing PP content, despite PP's greater resistance to ESCR than LDPE. The addition of SEBS-g-MA to the blend significantly improves the flexibility and ESCR performance of PP/LDPE blends with specific weight fractions.

Low-Density and High-Performance Fiber-Reinforced PP/POE Composite Foam via Irradiation Crosslinking.

This study addresses the challenge of achieving foam with a high expansion ratio and poor mechanical properties, caused by the low melt viscosity of semi-crystalline polypropylene (PP). We systematically employ a modification approach involving blending PP with polyolefin elastomers (POE), irradiation crosslinking, and fiber reinforcement to prepare fiber-reinforced crosslinked PP/POE composite foam. Through optimization and characterization of material composition and processing conditions, the obtained fiber-reinforced crosslinked PP/POE composite foam exhibits both low density and high performance. Specifically, at a crosslinking degree of 12%, the expansion ratio reaches 16 times its original value, and a foam density of 0.057 g/cm3 is reduced by 36% compared to the non-crosslinked PP/POE system with a density of 0.089 g/cm3. The density of the short-carbon-fiber-reinforced crosslinked sCF/PP/POE composite foam is comparable to that of the crosslinked PP/POE system, but the tensile strength reaches 0.69 MPa, representing a 200% increase over the crosslinked PP/POE system and a 41% increase over the non-crosslinked PP/POE system. Simultaneously, it exhibits excellent impact strength, tear resistance, and low heat shrinkage. Irradiation crosslinking is beneficial for enhancing the melt strength and resistance to high temperature thermal shrinkage of PP/POE foam, while fiber reinforcement contributes significantly to improving mechanical properties. These achieve a good complementary effect in low-density and high-performance PP foam modification.

The Crystallization Behavior of L-Poly(lactic acid)/Polypropylene Blends: The Acceleration for Both L-Poly(lactic acid) and Polypropylene

The Crystallization Behavior of L-Poly(lactic acid)/Polypropylene Blends: The Acceleration for Both L-Poly(lactic acid) and Polypropylene

A novel approach for accurate determination of polyethylene and polypropylene content in polyolefin blends and recyclates by cross-fractionation chromatography

The accurate characterization of post-consumer recycled (PCR) polyethylene (PE) and polypropylene (PP) blends is essential for repurposing them into higher-demand applications. This study improves the accuracy of the Temperature Rising Elution Fractionation coupled with Gel Permeation Chromatography (TREFxGPC) approach for both virgin and post-consumer recycled PP/PE blends. Model blends and virgin polymers were used to estimate polymer-specific IR-detector response factors. Moreover, a correction for the molecular weight-dependent amount of PP eluting in the TREF temperature range characteristic of PE was found. Accounting for these factors improved the results of the method, reducing the error in composition determination from 8 % to 2 %. Therefore, our approach provides better quantitative assessment capabilities for recycled blends. Furthermore, the refined TREFxGPC not only reliably determines the PCR PP/PE blend composition but also reveals their bivariate molecular weight and chemical composition distribution (MWD-CCD). Understanding the full microstructure of the blend can lead to superior recycled products, enabling the use of PCR in more demanding applications.

Upcycling Polyolefin Blends into High-Performance Materials by Exploiting Azidotriazine Chemistry Using Reactive Extrusion.

The revalorization of incompatible polymer blends is a key obstacle in realizing a circular economy in the plastics industry. Polyolefin waste is particularly challenging because it is difficult to sort into its constituent components. Untreated blends of polyethylene and polypropylene typically exhibit poor mechanical properties that are suitable only for low-value applications. Herein, we disclose a simple azidotriazine-based grafting agent that enables polyolefin blends to be directly upcycled into high-performance materials by using reactive extrusion at industrially relevant processing temperatures. Based on a series of model experiments, the azidotriazine thermally decomposes to form a triplet nitrene species, which subsequently undergoes a complex mixture of grafting, oligomerization, and cross-linking reactions; strikingly, the oligomerization and cross-linking reactions proceed through the formation of nitrogen-nitrogen bonds. When applied to polyolefin blends during reactive extrusion, this combination of reactions leads to the generation of amorphous, phase-separated nanostructures that tend to exist at polymer-polymer interfaces. These nanostructures act as multivalent cross-linkers that reinforce the resulting material, leading to dramatically improved ductility compared with the untreated blends, along with high dimensional stability at high temperatures and excellent mechanical recyclability. We propose that this unique behavior is derived from the thermomechanically activated reversibility of the nitrogen-nitrogen bonds that make up the cross-linking structures. Finally, the scope of this chemistry is demonstrated by applying it to ternary polyolefin blends as well as postconsumer polyolefin feedstocks.

Experimental analysis of blended nanocomposites processed using compression molded microwave process

Microwave irradiation has emerged as a versatile and efficient method for synthesizing polymer nanocomposites, offering advantages such as selectivity, speed, and effectiveness in heating materials. This study explores the blending of low-density polyethylene (LDPE) and polypropylene (PP) with carbon nanotubes (CNTs) using microwave processing. The nanocomposites were characterized for their mechanical properties through tensile and fracture toughness tests. Results indicate that LDPE/CNT blended with PP/CNT pellets exhibited improved Young’s modulus and fracture toughness, while LDPE/CNT blended with PP/CNT powder showed enhanced stiffness and fracture toughness. The critical stress intensity factor ( KIC) increased with higher proportions of PP in both cases, signifying improved crack resistance. XRD and SEM analyses confirmed enhanced crystallinity and proper bonding between polymers and CNTs. Overall, this study demonstrates the potential of microwave processing in producing nanocomposites with enhanced mechanical properties, offering a promising avenue for engineering applications.

Polypropylene blends: Impact of long chain-branched polypropylene on crystallization of linear polypropylene

Polypropylene blends: Impact of long chain-branched polypropylene on crystallization of linear polypropylene

Dual functionalized copper nanoparticles for thermoplastics with improved processing and mechanical properties and superior antibacterial performance.

The utilization of metal nanoparticles for antibacterial thermoplastic composites has the potential to enhance the safety of human and animal life by mitigating the spread and transmission of foodborne pathogenic bacteria. The dispersion, antioxidant and antimicrobial activities of metal nanoparticles directly affect the application performance of the composites. This study focused on achieving amine-carboxyl co-modified copper nanoparticles (Cu-AC) with excellent antioxidant properties and monodispersity through in situ grafting of amine and carboxyl groups onto the surface of copper nanoparticles via ligand interaction. Polyacrylic acid's extended carbon chain structure was utilized to improve its dispersion and antioxidant properties, and its antibacterial properties were synergistically enhanced using secondary amines. It was found that Cu-AC possesses high antibacterial properties, with a minimum inhibition concentration of 0.156 mg mL-1. Antibacterial masterbatches and their composites (polypropylene/Cu) manufactured by melt blending of polypropylene and Cu-AC exhibited excellent antibacterial rates of up to 90% and 99% at 300 ppm and 700 ppm Cu-AC, respectively. Additionally, Cu-AC bolstered the thermal degradation, processing and mechanical properties of polypropylene. The successful implementation of this product substantiates the potential applications of polypropylene/Cu composite materials across diverse industries.

Investigation of synergetic, kinetics, thermodynamics, and batch studies of polypropylene-bakelite co-pyrolysis

This study explores the co-pyrolysis recycling of the Polypropylene-Bakelite blend to improve the kinetics, thermodynamics, and conversion of thermal degradation of bakelite into useful products. The thermogravimetry analysis of the blend was conducted from ambient to 1000 °C at various heating rates in an N2 atmosphere. Thermogravimetric-Differential thermogravimetry curves revealed four steps of pyrolytic degradation, including two major weight loss steps (220–420 °C and 420–550 °C). The blending of polypropylene with Bakelite caused a shift in the pyrolytic degradation temperature zone and a synergetic effect. The pyrolytic degradation of the blended sample followed the F3 order-based mechanism with an average activation energy of 151 kJ/mol at 220–420 °C and the P3/2 nucleation mechanism with an average activation energy of 306 kJ/mol at 420–550 °C. The blend produced 47.66 % oil, 11.1 % wax, 15.1 % residue, and 26.14 % non-condensable gas during batch pyrolysis at 450 °C. The Gas Chromatography-Mass Spectrometry and Fourier Transform Infrared Spectroscopy analyses revealed that the oil contained 18.86 % saturated hydrocarbons (C8-54), 20.33 % unsaturated hydrocarbons (C7-19), and 60.81 % oxygenated compounds (C9-41) that could be used as transportation fuel.

Identification of Plastics in Mixtures and Blends through Pyrolysis-Gas Chromatography/Mass Spectrometry.

In this paper, the possibility of detecting polymers in plastic mixtures and extruded blends has been investigated. Pyrolysis-gas chromatography/mass spectrometry (py-GC/MS) allows researchers to identify multicomponent mixtures and low amounts of polymers without high spatial resolution, background noise and constituents mix interfering, as with molecular spectrometry techniques normally used for this purpose, such as Fourier transform infrared spectroscopy (FTIR) and Raman spectroscopy and differential scanning calorimetry (DSC). In total, 15 solid mixtures of low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), polyamide (PA) and polycarbonate (PC) in various combinations have been qualitatively analyzed after choosing their characteristic pyrolysis products and each polymer has been detected in every mix; thus, in extruded blends of high-density polyethylene (HDPE), PP and PS had varying weight percentages of the individual constituents ranging from 10 up to 90. Moreover, quantitative analysis of these polymers has been achieved in every blend with a trend that can be considered linear with coefficients of determination higher than 0.9, even though the limits of quantification are lower with respect to the ones reported in the literature, probably due to the extrusion process.

Dielectric Breakdown Strength of Polypropylene Blended with Ethylene Octene Elastomers

Polymer blends have become a major focus of research in exploring the potential for new dielectric material applications, particularly in the insulation of high voltage systems. In the current research area, polypropylene (PP) is being investigated as an insulation material for high voltage alternating current and direct current power cables. However, PP must be treated with rubbery materials such as elastomers to lessen its overall stiffness for power cable extrusion. While various promising results have been published on the potential use of PP/elastomer blends as dielectric materials, the dielectric effects of adding ethylene octene elastomer to PP have been less explored. This paper discusses the alternating current (AC) and direct current (DC) breakdown strength of PP that contains different amounts of ethylene octene elastomer (10, 30, and 50 wt%). The addition of ethylene octene elastomer to PP affects the breakdown performance of the blend systems under both AC and DC fields. Significantly, an increase in elastomer contents results in a notable reduction in the AC and DC breakdown strength. A discussion is presented on the mechanisms underlying the change in the breakdown strength caused by the different amounts of ethylene octene elastomer blended with PP.

Thermal oxidation of blends of polypropylene and polyamide 6/66. Effect of inhibition

The thermal oxidation of the blends of isotactic polypropylene (PP) and mixed copolyamide PA6/66 has been studied in a wide range of compositions: 0, 5, 10, 20, 30, 40, 50 and 100 wt % PA6/66. Data obtained by differential scanning calorimetry (DSC) and FTIR indicate the immiscibility of two polymer phases in the blends. The melting enthalpy of mixtures is increased during oxidation that is explained by chemi-crystallization of PP under PP oxidation. PA6/66 component is found to retard the growth of PP enthalpy during PP oxidation. According to DSC data on the PP/PA6/66 blends in air, PA6/66 phase greatly enhances the oxidation onset temperature of the PP/PA6/66 blends thus indicating the improved thermal stability of new material. The oxygen consumption of the PP/PA6/66 blends at 130°C proceeds with a large oxidation induction time (OIT) which is increased with increase in PA6/66 content. After OIT is ended, a constant oxidation rate is established, which is characteristic of the autoxidation mechanism. Kinetic analysis of the thermal oxidation of the PP/PA6/66 blends was carried out on the base of two models of polyolefin autooxidation with hydroperoxide decomposition via the 1st or the 2nd order reaction. The both models were found to describe the experimental kinetic curves of the oxygen consumption. Two possible explanations of the inhibition of PP oxidation by PA6/66 phase are discussed. The migration of active radicals from the PP phase to the PA6/66 phase with their transformation into low-active PA6/66 radicals may be responsible for inhibition and an increase in OIT of PP. Another mechanism of OIT increase may be related with a change in the structure of the PP/PA6/66 blends depending on PA6/66 content.

Investigation of Crystallization, Morphology, and Mechanical Properties of Polypropylene/Polypropylene-Polyethylene Block Copolymer Blends.

Polyethylene (PE)-based elastomers are the ideal choice for enhancing the compatibility of polypropylene/polyethylene (PP/PE) blends and improving the mechanical properties of PP-based materials. However, the issue of blend systems lies in the interplay between the crystallization processes. Therefore, we investigated the crystallization behavior during the cooling process of a new generation of PP/PE block copolymers (PP-b-PE) and random polypropylene (PPR, a copolymer of propylene and a small amount of ethylene or an alpha-olefin) blends using in-situ X-ray diffraction/scattering and differential scanning calorimetry (DSC) techniques. We also conducted mechanical performance tests on PPR/PP-b-PE blends at room temperature and low temperature (-5 °C). The results indicate that during the cooling process, the PP phase of PP-b-PE will follow the PPR to crystallize in advance and form a eutectic mixture, thereby enhancing the compatibility of PP/PE. Moreover, the PPR/PP-b-PE blend will form stable β-(300) crystals with excellent mechanical properties. Due to the improved compatibility of PP/PE with PP-b-PE, PE crystals are dispersed within PP crystals, providing bonding that improves the toughness of PPR under the low stiffness failure conditions of PPR/PP-b-PE blends, thereby enhancing their impact performance at low and room temperatures. This research has great significance for both recycling waste plastics and enhancing the low-temperature toughness of PPR.

A pragmatic approach to analyze the ability of ethylene‐octene copolymer in the long chain branching of polypropylene in molten and solid state

AbstractThe investigation of chain branching in polypropylene (PP) holds significant importance for comprehending the impact of structural modifications on the properties of PP. The utilization of ethylene‐octene copolymer (EOC) presents a valuable opportunity to examine the influence of branching density on the ability of electron beam irradiation or a chemical agent in a PP blend. The introducing long chain branches (LCB) into PP can enhance its mechanical properties, particularly impact strength. This characteristic is of particular significance in applications where the material is subjected to mechanical stress, such as automotive components or packaging materials. Blends of PP/EOC were produced using 20 and 30 wt% of EOC and 0.5 phr trimethylolpropane trimethacrylate (TMPTMA) monomer. To evaluate the efficiency of branching in both solid and molten states, irradiated samples and samples mixed with dicumyl peroxide (DCP) were selected. The rheological properties of the molten blends in shear and extensional modes were assessed, and their morphology was examined using scanning electron microscopy. The existence of LCB in all samples was confirmed through dynamic viscoelastic measurements. It was concluded that although the irradiation promoted chain scission within the backbone, which resulted in long chain branching, DCP created LCB on the backbone chains of PP through chemical reaction in the melt state. Additionally, the strain hardening constant (n) was calculated, and its value for the irradiated sample PP/EOC 80/20 was 0.19, whereas its value for this blend when employing DCP was 0.14. While the complex viscosity of irradiated blend (8764 Pa.s) was greater than that of melt state branched blend (8377 Pa.s) at 0.1 rad/s, in the higher frequencies it became smaller due to the more effective creation of long chain branches through peroxide grafting in the molten state. The results of the study verified the presence of LCB in the materials by observing longer relaxation time and strain hardening behavior.Highlights The chain branching of PP/EOC blends was investigated in both the melt state and solid state through the presence of TMPTMA monomer. The effectiveness of TMPTMA monomer in grafting was mostly notable in the molten state. The steady state viscosity of LCB‐(PP/EOC) was higher in the presence of dicumyl peroxide compared to irradiated PP/EOC. The samples containing 80 wt% of PP exhibited longer side branches compared to the sample with 70 wt% of PP according to shear and extensional rheometry. The induced side chain branches resulting from irradiation and the use of dicumyl peroxide help increase the miscibility of the polymers to a similar extent.

Accelerated crystallization and crystal-crystal transition of PB induced by PP with optimized content

Isotactic polybutene-1 (PB)/isotactic polypropylene (PP) blends, typical crystalline/crystalline polymer blends with low-melting-temperature (Tm) PB and high-Tm PP, exhibit complicated interactions between their components in both molten and solid states. However, the intrinsic influences of PP component on crystallization of PB form II, form II-I transformation, and the dependence of these phase transitions on PP content are unclear. In this work, the influences of PP content ranged from 5 wt% to 40 wt% on PB crystallization were investigated. It was found that the content of PP played significant roles on the phase morphologies of the blends in molten state and then the subsequent crystallization of PB whatever in form II or form I. The PP components with ≤20 wt% addition acting as heterogeneous nucleation sites promoted crystallization nucleation, increased the crystallinity and lamellar thickness of PB, accelerated PB form II-I transformation and increased transformation degree with the increase in PP content. Whereas, the PP components with ≥30 wt% incorporation reduced the crystallinity and lamellar thickness of PB, retarded PB form II-I transformation and transformation degree with the increase in PP content. Interestingly, the PB/PP (80/20) blend presented the fastest II-I transformation rate as well as the highest transformation degree of PB. The dependence of crystallization and crystal structures of PB form II, form I, and form II-I transformation kinetics on PP concentration was discussed. PB form I′ was not observed in the present study. This work provides a theoretical and practical guide for the preparation of novel PB materials with desired structures and excellent performance, especially with anxiously accelerated crystal-crystal transition and transition degree of PB.

The effect of expanded graphite and paraffin wax on the morphological, thermal, and rheological properties of PP/EVA blend

The study investigated the effect of paraffin wax, expanded graphite, and their dispersion on the properties of the blend of polypropylene (PP) and ethylene vinyl acetate (EVA). The idea is to reduce interfacial tension in blends of PP and EVA while enhancing the properties of blends in the process. The chosen optimum contents of the paraffin wax and EG in the 80/20 PP/EVA blend were 10 and 6 wt.%, respectively. The morphological features show that the expanded graphite (EG) particles had high affinity for each other. Moreover, EG filler particles are localized inside the minor EVA phase and some at the interface. Rheological properties revealed that the flow of the binary composites increased when 10 wt.% wax is added suggesting that wax enhanced the processability of the composites. The Cole-Cole plots deviated from the semi-circular arc suggesting heterogeneity in the blend and PP/EVA/Wax/EG composite. The addition of paraffin wax and EVA delayed crystallization of PP, while earlier crystallization of PP was promoted by the presence of EG. Generally, all samples caught fire after 10 s, started dripping and are thus given a V-2 rating according to the Underwriters Laboratories test standard 94 results (UL-94).

Brittle–Ductile Transitions of Rubber Toughened Polypropylene Blends: A Review

Brittle–Ductile Transitions of Rubber Toughened Polypropylene Blends: A Review

On the Mechanical, Thermal, and Rheological Properties of Polyethylene/Ultra-High Molecular Weight Polypropylene Blends.

The novel ultra-high molecular weight polypropylene (UHMWPP) as a dispersed component was melt blended with conventional high-density polyethylene (PE) and maleic anhydride grafted-polyethylene (mPE) in different proportions through a kneader. Ultra-high molecular weight polypropylene is a high-performance polymer material that has excellent mechanical properties and toughness compared to other polymers. Mechanical, thermal, and rheological properties were presented for various UHMWPP loadings, and correlations between mechanical and rheological properties were examined. Optimal comprehensive mechanical properties are achieved when the UHMWPP content reaches approximately 50 wt%, although the elongation properties do not match those of pure PE or mPE. However, it is worth noting that the elongation properties of these blends did not match those of PE or mPE. Particularly, for the PE/UHMWPP blends, a significant drop in tensile strength was observed as the UHMWPP content decreased (from 30.24 MPa for P50U50 to 13.12 MPa for P90U10). In contrast, the mPE/UHMWPP blends demonstrated only minimal changes in tensile strength (ranging from 29 MPa for mP50U50 to 24.64 MPa for mP90U10) as UHMWPP content varied. The storage modulus of the PE/UHMWPP blends increased drastically with the UHMWPP content due to the UHMWPP chain entanglements and rigidity. Additionally, we noted a substantial reduction in the melt index of the blend system when the UHMWPP content exceeded 10% by weight.

Characterization of PS/PP/HDPE/LDPE Polymer Blend Obtained from Plastic Waste Collected on Beaches in Ilhéus-Bahia, Brazil.

A large volume of polymeric waste is generated in cities, and some of this reaches the sea and beaches. This waste stays for hundreds of years, damaging marine environments and organisms. To minimize the effects of pollution, collection and recycling allow a return to the production chain. This research aims to produce and evaluate a polymeric mixture obtained via processing plastic waste collected on the beaches of the city of Ilhéus-Bahia. Subsequently, the mixture is converted into a granulated form for application as fine aggregate in the production of cementitious matrices. A polymer blend of polystyrene, polypropylene, and high- and low-density polyethylene was obtained and evaluated by thermal, morphological, and mechanical tests in three processing stages. The degradation temperatures were close for the three processing stages and the level of processing influenced the mechanical strength. As for elastic modulus and deformation, there was no significant difference in using the mixture processed once or twice. The results showed that the reuse of the waste is applicable, the mixture presented a compact, reasonably homogeneous material with different morphology. Therefore, this work finds importance in the possibility of promoting waste recycling and adding value to a material that would become waste, thus showing its potential for application in the construction industry as an addition to cementitious mixtures and leading to savings in inputs.