Polypropylene/nylon 6 blends: Phase distribution morphology,rheological measurements,and structure development in melt spinning

A series of polypropylene (PP)/nylon 6 (N6) blends of composition 75/25, 50/50, and 25/75 have been prepared in a screw extruder combined with a Koch static mixer. The phase morphology was observed with a scanning electron microscope. The influence of heating in the reservoir of a rheometer followed by subsequent extrusion through a capillary on the phase morphology was investigated. Phase size growth as a function of time was observed under quiescent and mild deformation rate conditions. The discrete phase size was observed to decrease with increasing extrusion rate through dies. The shear viscosity and principal normal stress difference of the blends were measured as a function of composition. The crystalline orientation of both polypropylene and nylon 6 in blend melt spun fibers was characterized by wide angle X-ray diffraction and interpreted in terms of Hermans–Stein orientation factors. The orientation increases with drawdown ratio. The orientation factors for the polypropylene phase vary with spinline stress in a manner independent of composition and identical to that for pure polypropylene. Extracting melt spun blend fibers with formic acid has produced small-diameter polypropylene minifilaments with diameters of the order of microns.     

The phase inversion and morphology of nylon 1010/polypropylene blends

Noncompatibilized and compatibilized blends of nylon 1010/PP blends having five different viscosity ratios were prepared by melt extrusion. Glycidyl methacrylate-grafted-polypro-pylene (PP-g-GMA) was used as the compatibilizer to enbance the adhesion between the two polymers and to stabilize the blend morphology. The effect of the viscosity ratio on the morphology of nylon 1010/polypropylene blends was investigated, with primary attention to the phase-inversion behavior and the average particle size of the dispersed phase. The relationship between the mechanical properties and the phase-inversion composition was investigated as well. Investigation of the morphology of the blends by microscopy indicated that the smaller the viscosity ratio (ηpp/ηpa) the smaller was the polypropylene concentration at which the phase inversion took place and polypropylene became the continuous phase. The compatibilizer induced a sharp reduction of particle size, but did not have a major effect on the phase-inversion point. An improvement in the mechanical properties was found when nylon 1010 provided the matrix phase. © 1996 John Wiley & Sons, Inc.     

Electron‐beam processing of nylon 6 and HNBR blends. Part II: development of high strength,heat‐ and oil‐resistant thermoplastic elastomers

The effects of electron‐beam irradiation on morphology, mechanical properties and on the heat and hot oil resistance of the thermoplastic elastomeric blend of 30:70 and 70:30, nylon 6 and hydrogenated nitrile rubber (HNBR) were investigated over the dose range 0–8 Mrad. The insoluble content of blends increased with increase in the radiation dose. The morphology of the blend was studied in scanning electron microscopy, with special reference to the effect of radiation prior to processing via injection molding. Irradiated pellets showed better mechanical properties after injection molding compared with irradiated sheets at low radiation dose. The observed differences in mechanical properties are explained on the basis of morphology of the blend. The blend properties were also found to have a strong dependence on nylon content. It was found that the blends rich in nylon had superior mechanical properties, hot oil and solvent resistance, whereas blends with higher HNBR content had better set and heat resistance. The effect of radiation on interaction in these blends was also evaluated and was found to induce possible inter‐chain crosslinking in the blends. Copyright © 2006 Society of Chemical Industry     

Compatibility effect of reactive copolymers on polypropylene/polyamide 6 blends from commingled plastic wastes

We report the compatibility effect on a recycled polypropylene/nylon (75/25) blend processed with reactive copolymers on the basis of morphological, mechanical, and rheological characteristics. Via a scanning electron microscopy investigation, we found improved surface morphologies with regular and fine domains in a recycled polypropylene/nylon (75/25) blend compatibilized with copolymers containing maleic anhydride as a reactive functional group [styrene–(ethylene/butylene)–styrene‐graft‐maleic anhydride copolymer and polypropylene‐graft‐maleic anhydride]. Large increases in both the mechanical and rheological properties with the addition of the styrene–(ethylene/butylene)–styrene‐graft‐maleic anhydride copolymer could be interpreted with respect to a specific structure at the interface, showing a strong interfacial adhesion between recycled polypropylene and nylon. To confirm the existence of this structure, we used various dynamic rheological parameters: the Cox–Merz rule, storage modulus, and phase angle. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 1188–1193, 2006     

Effect of blend ratio on bulk properties and matrix-fibril morphology of polypropylene/nylon 6 polyblend fibers

Ternary blends of polypropylene (PP), nylon 6 (N6) and polypropylene grafted with maleic anhydride (PP/N6/PP-g-MAH) as compatibilizer with up to 50 wt% of N6 were investigated. PP-g-MAH content was varied from 2.5 to 10%. Blends of the two polymers PP/N6 (80/20) without the compatibilizer were also prepared using an internal batch mixer and studied. The ternary blends showed different rheological properties at low and high shear rates. The difference depended on the amount of N6 dispersed phase. Co-continuous morphology was observed for the blend containing 50% N6. This blend also exhibited higher viscosity at low shear rate and lower viscosity at high shear rates than the value calculated by the simple rule of mixture. At higher shear rates, viscosity was lower than that given by the rule of mixture for all blend ratios. An increase in viscosity was observed in the 80/20 PP/N6 blend after the concentration of the interfacial agent (PP-g-MAH) was increased. Polyblends containing up to 30% N6 could be successfully melt spun into fibers. DSC results showed that dispersed and matrix phases in the fiber maintained crystallinity comparable to or better than the corresponding values found in the neat fibers. The dispersed phase was found to contain fibrils. By using SEM and LSCM analyses we were able to show that the N6 droplets coalesced during melt spinning which led to the development of fibrillar morphology.     

Morphology of compatibilized ternary blends of polypropylene,nylon 66, and polystyrene

The morphologies of a ternary blend of nylon 66 and polystyrene in a polypropylene matrix with and without compatibilization by an ionomer resin (for nylon 66) and a styrene‐block‐ethylene‐co‐butylene‐block‐styrene (SEBS) copolymer (for polystyrene) were investigated by transmission electron microscopy (TEM) of stained thin sections. The morphology found with the two compatibilizers (a five‐component mixture) was essentially that of the binary blends of nylon 66/polypropylene and of polystyrene/polypropylene with their respective compatibilizers, indicating no gross interference between the two compatibilization systems. However, several interactions were discerned: 1) an association of the polystyrene with the nylon in the compatibilized blends (partial wetting), 2) a presence of larger particles when both compatibilizers were added to the binary blends, and 3) a possible synergism, in which less of each compatibilizer was needed when they were both present. Polym. Eng. Sci. 46:385–398, 2006. © 2006 Society of Plastics Engineers.     

Yttria–polystyrene–polypropylene composite for fine dyeable fibers

Fine polypropylene fiber has many excellent properties, but it is difficult to dye because of the absence of dye sites in the molecular chain and high crystallinity. Fine polypropylene/hybrid polystyrene (yttria) fiber melt‐spun from blends of polypropylene and a small amount of nanohybrid polystyrene with modified yttria incorporated was prepared to improve the dyeing properties. The dyeability, orientation, degree of crystallinity, phase morphology, and mechanical properties of pure polypropylene and the blend fibers were investigated. It was found that the crystallinity and morphology of these phases in the blend systems were different. With the existence of nanohybrid polystyrene, the fine modified polypropylene filaments had practical mechanical properties, the amorphous region of the polypropylene/hybrid polystyrene (yttria) fiber increased, and the modified polypropylene fiber dyed easily and had good fastness to soaping because of the complexation of the disperse dye and yttrium in the blend system. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Polyaniline–polypropylene melt‐spun fiber filaments: The collaborative effects of blending conditions and fiber draw ratios on the electrical properties of fiber filaments

A melt‐processable polyaniline complex was blended with polypropylene under different mixing conditions and melt‐spun into fiber filaments under different draw ratios. The conductivity, electrical resistance at different voltages, and morphological characteristics of the prepared fibers were investigated. The morphology of this two‐phase blend was demonstrated to have a large effect on the conductivity level and the linearity of the resistance–voltage relationship of the blend fibers. Two factors had substantial effects on the morphology and electrical properties of the fibers. They were the size of the initial dispersed conductive phase, which depended on the melt blending conditions, and the stress applied to orient this phase to a fibril‐like morphology, which was controlled by the draw ratio of the fiber. The two factors were shown to be associated with each other to maintain an appropriate balance of fibril formation and breakage and to create continuous conductive pathways. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Effect of viscosity ratio and processing conditions on the morphology of blends of liquid crystalline polymer and polypropylene

The effect of viscosity ratio and processing conditions on LCP/PP blend morphology was studied. The viscosity ratio (η_LCP/η_PP) was varied from 0.1 to 3.6 by using five different polypropylene grades as the matrix and two LCPs as the dispersed phase (20 wt %). The most spontaneous fiber formation was achieved when the viscosity ratio was between 0.5 and 1. In addition to shear forces, elongational forces are important in achieving a highly fibrillar structure and significant mechanical reinforcement. The lubricating effect induced by the low viscosity of LCP was most pronounced for the blends exhibiting a fibrillar morphology. The morphologies of blends produced by different mixing equipment differed only slightly. The greatest variation in the mixing efficiency was found for blends whose components had totally dissimilar melt viscosities. The slight differences in morphology due to melt blending in dissimilar equipment were decreased after injection molding, whereas the differences in morphology due to dissimilar viscosity ratios were still evident in the injection molded blends. Thus, the viscosity ratio at processing in the actual processing conditions is of great importance. © 1994 John Wiley & Sons, Inc.     

Laminar morphology development using hybrid EVOH–nylon blends

Properties of blends having two types of hybrid dispersed phases as laminar morphology were investigated. The hybrid dispersed phases were prepared by preblending nylon and ethylene–vinyl alcohol (EVOH) in solid state (E + N) and in melt state (E/N). Oxygen and toluene barrier properties through the hybrid-dispersed phases in low-density polyethylene (LDPE) matrix were analyzed considering the morphological changes (number and size of layers). Oxygen barrier properties of the blends of LDPE–E + N hybrid dispersed phase having separate domains of nylon and EVOH were found to be linearly dependent on EVOH composition in the blend, but toluene barrier properties of the blends exhibited negative deviation. The other hybrid dispersed phase (E/N) in LDPE matrix, having comingled dispersed phase of nylon and EVOH, exhibited positive deviations in both oxygen and toluene barrier properties. Tensile properties also showed positive deviation. Basic studies on the melt blend (E/N) of EVOH and nylon 6 showed some miscibility, which was revealed from melting point depression, and positive deviation in complex viscosity and tensile properties of the blend. © 1998 John Wiley & Sons, Inc. J Appl Polym Sci 67:2001–2014, 1998     

Phase morphology and melt rheological behavior of uncrosslinked and dynamically crosslinked polyolefin blends: role of macromolecular structure

Thermoplastic vulcanizates (TPVs) based on polypropylene (PP) with ethylene–octene copolymer (EOC) and ethylene propylene diene rubber (EPDM) have been prepared by co-agent-assisted peroxide crosslinking system. The study was pursued to explore the influence of two dissimilar polyolefin polymers having different molecular architecture on the state and mode of dispersion of the blend components and their influence on melt rheological properties. The effects of dynamic crosslinking of the PP/EOC and PP/EPDM have been compared with special reference to the concentration of crosslinking agent and ratio of blend components. Morphological analyses show that, irrespective of blend ratio, dynamic vulcanization exhibits a dispersed phase morphology with crosslinked EOC or EPDM particles in the continuous PP matrix. It was found that viscosity ratio plays a crucial role in determining the state and mode of dispersion of blend components in the uncrosslinked system. The lower viscosity and torque values of uncrosslinked and dynamically crosslinked blends of PP/EOC in the melt state indicates that they exhibit better processing characteristics when compared to corresponding PP/EPDM blends.     

The development of laminar morphology during extrusion of polymer blends

Studies of the microstructure and permeability of extruded ribbons of polypropylene (PP)/ethylene vinyl alcohol copolymer (EVOH) and polyethylene (PE)/polyamide-6 (PA-6) blends have shown that it is possible to control the flow-induced morphology to generate discontinuous overlapping platelets of EVOH or PA-6 dispersed phase in a PP or HDPE matrix phase. The effects of the following factors on morphology development and blend properties were considered: blending sequence, melt temperature, composition, compatibilizer level, die design, screw type, and cooling conditions. The impact properties and interfacial adhesion of laminar blends of PP and EVOH were improved without diminishing the barrier properties. The oxygen and toluene permeability of extruded samples with EVOH content of 25 vol% resembled values obtained with multilayer systems. Processing conditions had a major influence on the morphology of blends of high density polyethylene and polyamide-6 (HDPE/PA-6), and, under special processing conditions, laminar morphology was obtained in this system. The toluene permeability of extruded ribbons of HDPE/PA-6 blends was in the range obtained with multilayer systems.     

Prodegradant effect of titanium dioxide nanoparticulates on polypropylene–polyhydroxybutyrate blends

Polymers are gradually replacing conventional materials in various sectors of the economy because of their low cost and broad functionality. However, the high stability of polymers under most environmental conditions can lead to their accumulation in the form of waste. Polyhydroxybutyrate (PHB) is an alternative because of its biodegradability, but it is usually expensive and brittle. These aspects can be improved through the formation of blends, such as with polypropylene (PP). The objective of this study was to investigate the possibility of using titanium dioxide (TiO₂) nanoparticles as a prodegradant agent in the PP–PHB–TiO₂ system through the evaluation of the effects of these nanoparticles under UV light on the structure and properties of the materials. Samples were produced through extrusion and injection molding and were characterized by their mechanical and thermal properties and structural analyses. The results show that the TiO₂ nanoparticles were able to act as a prodegradant agent for the PP–PHB blend; they also successfully improved some of the mechanical and dynamic mechanical properties of the blend. However, a TiO₂ nanoparticle content higher than 7.5 wt % was not able to extend the photodegradation process further, possibly as a consequence of the agglomeration of nanoparticles during the processing of these more concentrated blends. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46636.     

Comparison of structure development in quiescent crystallization,die extrusion and melt spinning of isotactic polypropylene and its compounds containing fillers and nucleating agents

The influences of fillers and nucleating agents on crystalline structure and stress induced crystallization of isotactic polypropylene were studied under a range of cooling and processing conditions, including die extrusion and melt spinning. Continuous cooling transformation curves were determined for polypropylene and various polypropylene filler compounds. The influence of spinline stress on crystallization was studied. The experiments reveal that under quiescent conditions, the kinetics and crystalline forms produced by the crystallization of polypropylene are dominated by nucleating fillers and impurities. The crystalline orientation‐spinline stress relationship, on the other hand, was found to be the same for polypropylene and its compounds. At high uniaxial stresses, kinetics and orientation development are dominated by homogeneous orientation crystallization.     

Morphology and mechanical properties of thermoplastic elastomers from nylon-nitrile rubber blends

Nylon-nitrile rubber blends having different plastic-rubber component ratios (100/0, 80/20, 70/30, 60/40, 50/50, 40/60, 30/70, 20/80, and 0/100) were prepared by melt mixing technique in a Rheocord-90 at a temperature set at 180°C. The mixing characteristics of the blends have been analyzed from the rheographs. The morphology of the blend was studied using optical and electron microscopies, with special reference to the effect of blend ratio. The micrographs indicate a two-phase system where the component having lower proportions was found to disperse in the major continuous phase. A cocontinuous morphology was observed for 50/50 composition. Mechanical properties of the blends have been measured according to standard test methods. The effect of blend ratio on the mechanical properties like tensile strength, tear strength, elongation at break, stress-strain behavior, and hardness has been analyzed. The influence of the strain rate on the mechanical properties has also been analyzed. The mechanical properties were found to have a strong dependence on the amount of nylon in the blend. It is found that the blends with higher proportions of nylon have superior mechanical properties. The observed changes in mechanical properties are explained on the basis of the morphology of the blend. Various theoretical models such as Series, Parallel, Halpin-Tsai, and Coran's equations have been used to fit the experimental mechanical data. © 1996 John Wiley & Sons, Inc.     

Interfacial tuning and designer morphologies of microporous membranes based on polypropylene/natural rubber nanocomposites

Microporous polypropylene (PP) nanocomposite membranes are in great demand in various fields such as energy harvesting, water purification, and other industrial applications. Thin films of PP/natural rubber (NR) blend nanocomposite have been prepared by melt mixing and the membranes are made porous by extracting the NR phase from the blend. The present study gives a better insight into the nanoparticle shape and localization-tailored porous morphology of PP membrane. Thermodynamic prediction of nanofiller localization and its impact on morphology were studied. 2D clay platelets in PP matrix tune the morphology of the porous membrane into lamellar, whereas spherical nanofillers give elongated spherical pores. The localization of nanoparticles was observed using transmission electron microscope, which is also confirmed from theoretical prediction of localization of nanofillers with the help of interfacial energy and surface tension. Thermal studies reveal that nanofillers enhance the thermal stability of polymers. Mechanical studies reveal that nanoparticles improve the mechanical properties of the system. 2D platelet shaped-nanofillers enhance the mechanical strength of the polymer up to 39%, which is higher than that obtained for 3D spherical nanofillers. Nanofiller shape and localization have a great influence in deciding the properties and porosity of the membrane.     

Conductive polymer blends with low carbon black loading: Polypropylene/polyamide

The electrical resistivity and morphology of polypropylene/nylon (PP/Ny) immiscible blends incorporated with carbon black (CB) were studied. CB was found to be preferentially located in the Ny phase or upon the Ny/PP interface. Blends with a co-continuous phase morphology depicted especially low resistivity values, due to a “double percolation” effect. The blend preparation sequence tends to affect the phase morphology, thus influencing the system's resistivity. Polymer polarity and crystallinity are important factors determining the blend's morphology, which relates directly to the electrical resistivity obtained.     

Morphological factors affecting the permeation resistance of nanocomposite blend films

The micro‐ and nanoscale morphologies of thin nanocomposite films comprising an immiscible nylon 6/polyethylene blend reinforced with modified sodium montmorillonite were found to substantially affect water vapor transmission rates (WVTRs). Maleic anhydride‐grafted high‐density polyethylene was incorporated as a compatibilizer between the nylon and polyethylene phases. Preferential incorporation of an organosilicate nanoclay in the nylon phase had a secondary effect on the overall blend morphology and thermal properties. Different degrees of phase continuity in the nanocomposite blend system were studied for their effect on WVTRs by varying the relative viscosities of the polymer phases. Transmission electron and atomic force microscopy were utilized to reveal the morphologies of the nanocomposite blends. POLYM. ENG. SCI., 54:1341–1349, 2014. © 2013 Society of Plastics Engineers     

Morphology and mechanical properties of polypropylene/polyamide 6 nanocomposites prepared by a two‐step melt‐compounding process

Polypropylene/polyamide 6 blends and their nanocomposites with layered silicates or talc were prepared in a melt‐compounding process to explore their mechanical performance. The thermomechanical behavior, crystallization effects, rheology, and morphology of these materials were studied with a wide range of experimental techniques. In all cases, the inorganic filler was enriched in the polyamide phase and resulted in a phase coarsening of the polypropylene/polyamide nanocomposite in comparison with the nonfilled polypropylene/polyamide blend. The mechanical properties of these nanoblends were consequently only slightly better than those of the pure polymers with respect to the modulus, whereas the impact level was below that of the pure polymers, reflecting the heterogeneity of the nanoblend. Polymer‐specific organic modification of the nanoclays did not result in a better phase distribution, which would be required for better overall performance. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 100: 283–291, 2006     

尼龙6／马来酸酐接枝聚乙烯共混物力学性能的研究

尼龙6与马来酸酐接枝聚乙烯在螺杆挤出机中挤出共混、通过扫(?)电镜对共混物的形态分析以及对共混物冲击强度、拉伸强度、吸水率的测定、发现共混体系中两相具有(?)好的相容性。共混物干态、低温冲击强度较尼龙6有大幅度提高,并且尼龙6的吸水性也得到了改善。