Effect of single‐mineral filler and hybrid‐mineral filler additives on the properties of polypropylene composites

The present study was carried out to determine the filler characteristics and to investigate the effects of three types of mineral fillers (CaCO₃, silica, and mica) and filler loadings (10–40 wt%) on the properties of polypropylene (PP) composites. The characteristics of the particulate fillers, such as mean particle size, particle size distribution, aspect ratio, shape, and degree of crystallinity were identified. In terms of mechanical properties, for all of the filled PP composites, Young's modulus increased, whereas tensile strength and strain at break decreased as the filler loading increased. However, 10 wt% of mica in a PP composite showed a tensile strength comparable with that of unfilled PP. Greater tensile strength of mica/PP composites compared to that of the other composites was observed because of lower percentages of voids and a higher aspect ratio of the filler. Mica/PP also exhibited a lower coefficient of thermal expansion (CTE) compared to that of the other composites. This difference was due to a lower degree of crystallinity of the filler and the CTE value of the mica filler. Scanning electron microscopy was used to examine the structure of fracture surfaces, and there was a gradual change in tensile fracture behavior from ductile to brittle as the filler loading increased. The nucleating ability of the fillers was studied with differential scanning calorimetry, and a drop in crystallinity of the composites was observed with the addition of mineral filler. Studies on the hybridization effect of different (silica and mica) filler ratios on the properties of PP hybrid composites showed that the addition of mica to silica‐PP composites enhanced their tensile strength and modulus. J. VINYL ADDIT. TECHNOL., 2009. © 2009 Society of Plastics Engineers     

Mechanical and thermal properties of talc and calcium carbonate filled polypropylene hybrid composites

The main aim of this work was to study and compare the mechanical and thermal properties of hybrid polypropylene (PP) composites and single‐filler PP composites. With two main types of mineral fillers—calcium carbonate (CaCO₃) and talc—PP composites of different filler weight ratios (talc/CaCO₃) were compounded with a twin‐screw extruder and then injection‐molded into dumbbell specimens with an injection‐molding machine. Tensile, flexural, and impact tests were performed to determine and compare the mechanical properties of the hybrid and single‐filler PP composites. A synergistic hybridization effect was successfully achieved; the flexural strength and impact strength were highest among the hybrids when the PP/talc/CaCO₃ weight ratio was 70:15:15. The nucleating ability of the fillers and its effects on the mechanical properties were also studied with differential scanning calorimetry. Because of the influence of talc as the main nucleating agent, the hybrid fillers showed significant improvements in terms of the nucleating ability, and this contributed to the increase in or retention of the mechanical properties of the hybrid composites. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 91: 3327–3336, 2004     

Comparison of the mechanical properties and interfacial interactions between talc,kaolin, and calcium carbonate filled polypropylene composites

Three types of mineral fillers—talc, calcium carbonate (CaCO₃), and kaolin (10–40 wt % filler loadings)—were compounded with polypropylene (PP) with a twin‐screw extruder. The composites were injection‐molded, and the effects of the filler loading on the mechanical, flow, and thermal properties for the three different types of filled composites were investigated. The aim was to compare their properties and to deduce prospective filler combinations that would yield hybrid PP composites in following studies. The results showed that in most cases, the strength and stiffness of the talc‐filled PP composites was significantly higher than those of the CaCO₃‐ and kaolin‐filled PP composites. However, CaCO₃, being a nonreactive filler, increased the toughness of PP. The kaolin‐filled PP composites also showed some improvement in terms of strength and stiffness, although the increases in these properties were not as significant as those of the talc‐filled PP composites. The effects of interfacial interactions between the fillers and PP on the mechanical properties were also evaluated with semiempirical equations. The nucleating ability of all three fillers was studied with differential scanning calorimetry, and the strongest nucleating agent of the three was talc, followed by CaCO₃ and kaolin. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 91: 3315–3326, 2004     

Thermal conductivity of polypropylene composites with hybrid fillers of boron nitride and vapor‐grown carbon fiber

High thermal conductivity fillers of boron nitride (BN) and vapor‐grown carbon fiber (VGCF) were used alone or incorporate to prepare polypropylene (PP) composites. The effects of filler content, particle size and shape, and single vs. hybrid BN/VGCF fillers were investigated with respect to the thermal conductivity of the PP composites. The thermal conductivity of PP/BN composites depended upon the content and particle size of the BN. Increased content and length of VGCF had the effect of increasing the thermal conductivity of the PP composites. Hybrid fillers were created with a mixture of medium‐sized BN and long‐length VGCF; hybrid BN/VGCF fillers enhanced the thermal conductivity of PP composites with a lower total content compared with PP composites containing only medium‐sized BN particles. POLYM. COMPOS., 37:936–942, 2016. © 2014 Society of Plastics Engineers     

Mechanical,flow, and morphological properties of talc‐ and kaolin‐filled polypropylene hybrid composites

Polypropylene (PP) hybrid composites have been produced by compounding two types of mineral fillers, viz., talc and kaolin with PP copolymer using a twin screw extruder. The PP hybrid composite was injection‐molded into dumbbell specimen for tensile, flexural, and impact properties characterizations. MFI and SEM studies were used to characterize the flow and morphological properties of the PP hybrid composites. The result shows that most of the hybrid composites showed a significant decrease in flow, tensile, flexural, and impact properties compared with the single filler‐filled PP composites. However, a hybridization effect was seen for the PPT20K10 hybrid composites, through the synergistic coalescence of positive characteristics from 20 wt % of talc and 10 wt % of kaolin. This hybrid formulation have given an economically advantageous material with the mechanical properties (tensile, flexural, and impact) comparable to those of the talc‐filled PP composites. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci 104: 434–441, 2007     

Polypropylene (PP)–Acacia mangiumcomposites: the effect of acetylation on mechanical and water absorption properties

Acacia mangiumwood flour (AMWF)–polypropylene (PP) composites were produced at different filler loading (20, 30, 40, and 50 w/w) and mesh no. (35, 60, 80, and 100 mesh). The AMWF–PP composites (using unmodified or modified wood flour) were compounded using a Haake Rheodrive 500 twin screw compounder. The mechanical and water absorption (WA) properties of modified (only at mesh no. 100) and unmodified AMWF–PP composites were investigated. Increase in the mesh number (35–100) of the unmodified AMWF showed increased flexural and impact properties. Flexural modulus exhibited higher properties as the filler loading increased (20–50). However, flexural and impact strength showed the opposite phenomenon. Water absorption and thickness swelling increased as the mesh number and filler loading increased. This has been attributed to the presence of hydrophilic hydroxyl groups of the filler. Modified AMWF–PP composites exhibited higher mechanical properties and good water resistance when compared to unmodified AMWF–PP composites at all values of filler loading. The evidence of the failure mechanism (from impact strength) of the filler–matrix interface was analyzed using scanning electron microscope.     

Single and hybrid mineral fillers (talc/silica and talc/calcium carbonate)‐filled polypropylene composites: Effects of filler loading and ratios

Properties of single and hybrid fillers with polypropylene (PP) composites were studied in this research work. The effect of filler loadings of three types of mineral fillers, namely talc, silica, and CaCO₃, was investigated. In hybrid composites systems, the effect of silica/talc (SI/T) and CaCO₃/talc (CC/T) filler ratios at 40 wt% was determined. Generally, the results demonstrated that SI/T has higher modulus than CC/T but both hybrids did not have a significant effect on PP strength. In thermal properties, both hybrids have a nucleating ability as they increase the crystallization temperature and onset of crystallization temperature of PP. Results of analysis by TGA revealed that SI/T increased thermal stability of PP composites more than CC/T. Better flammability of the SI/T system is exhibited by lower burning rates of SI/T than CC/T, which indicates better thermal stability of the hybrid system. J. VINYL ADDIT. TECHNOL., 20:160–167, 2014. © 2014 Society of Plastics Engineers     

Study of plastic compounds containing polypropylene and wood derived fillers from waste of different origin

The scope of the article was to study the perspectives of the using of wood derived fillers (WDF) from waste of different origin as fillers of polypropylene. The WDF used in this study was hard wood flour (HW), birch veneer polishing dust (VD) and tetra‐pack carton cellulose fiber (TC). Some mechanical strength parameters, water uptake in the static and cyclic test and resistance to fungal decay of polypropylene (PP) composites containing these three types of WDF were studied and compared with similar loading (40 wt %) talc‐filled PP. Composites containing TC and VD fibers as filler showed the highest flexural strength at three test temperatures (?40, +20, and +40°C) and flexural modulus and tensile strength at plus temperatures. On the other hand talc‐filled PP exhibited greatest flexural modulus at minus temperature, greatest impact strength at room temperature and best flow ability. Significant difference was observed between PP composites with HW and VD fillers regarding water uptake in cyclic tests, however flexural strength and modulus change of composites were reversible after drying. No weight loss of WDF/PP composites was observed after 6 week exposure to brown‐ and white‐rot fungi, however, degradation of the surface of samples was detected by SEM. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Effect of γ-Radiation on the Mechanical Performance of Hybrid Rice Straw/Seaweed-Polypropylene Composites

Hybrid composites of rice straw (Rs)/seaweed (Sw) and polypropylene (PP) were prepared at a fixed filler ratio of 30:70 and variable ratio of the two reinforcements, viz. 30:0, 25:5, 20:10, 10:20, 0:30 by weight. Mechanical properties of the composites such as tensile strength (TS), bending strength (BS), impact strength (IS) and elongation at break (Eb%) were investigated and the composite formulation of 20:10:70 (Rs:Sw:PP) was found to be optimum that showed TS = 2.8 MPa, BS = 68 N/mm², IS = 2.5 kJ/mm² and Eb = 50%. For better compatibility, Rs and Sw were subjected to surface treatment using various intensities of γ-radiation to prepare improved hybrid composites. γ-irradiated filler hybrid composites significantly enhanced mechanical properties and the composite in which fillers were irradiated at 100 krad achieved maximum enhancement with TS = 35 MPa, BS = 75 N/mm², IS = 2.7 kJ/mm² and Eb = 68%. Water absorption capacity of the different composites was also studied and irradiated filler composites showed less water uptake.     

Influence of mineral fillers on the fire retardant properties of wood‐polypropylene composites

The effects of mineral fillers on the fire retardancy of wood‐polypropylene composites have been studied. Wood‐polypropylene composites containing mineral fillers have been compounded in a conical twin‐screw extruder. A composite manufactured without any mineral filler addition has been used as a reference. The flame resistance properties of the composite materials have been studied using the cone calorimeter. The results show that the introduction of mineral fillers into the wood‐polypropylene composites has a favourable effect on the fire resistance properties of the composite materials. The reaction‐to‐fire properties have been improved according to the fire classification of construction products based on the Euroclass system. Copyright © 2012 John Wiley & Sons, Ltd.     

Influence of grafted polypropylene on the mechanical properties of mineral‐filled polypropylene composites

The purpose of this work was to study how mineral fillers would behave in a polypropylene (PP) matrix when PP modified with maleic anhydride (MA) and/or itaconic acid (IA) was used as a coupling agent in the preparation of mineral‐filled PP composites. The composites were characterized with tensile mechanical measurements and morphological analysis. The optimum amount of the coupling agent to be used to obtain composites with improved mechanical properties was established. The results indicated that these coupling agents enhanced the tensile strength of the composites significantly, and the extent of the coupling effect depended on the nature of the interface that formed. The incorporation of coupling agents enhanced the resistance to deformation of the composite. The behavior of IA‐modified PP as a coupling agent was similar to that of a commercial MA‐modified PP for the filled PP composites. Evidence of improved interfacial bonding was revealed by scanning electron microscopy studies, which examined the surfaces of fractured tensile test specimens; their microstructures confirmed the mechanical results with respect to the observed homogeneous or optimized dispersion of the mineral‐filler phase in these composites. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 103: 2343–2350, 2007     

Investigation on flammability of rigid polyurethane foam‐mineral fillers composite

This study investigates the incorporation of castor oil–based rigid polyurethane foam with mineral fillers feldspar or kaolinite clay in order to enhance the mechanical, thermal, and flame retardant properties. Influence of mineral fillers on the mechanical strength was characterized by compressive strength and flexural strength measurement. Thermogravimetric analysis (TGA) was performed to diagnose the changes in thermal properties, while cone calorimeter test was performed to ascertain the flame retardancy of the mineral filler–incorporated rigid polyurethane foam composites. Results showed that the foams incorporated with mineral filler demonstrated up to 182% increase in compressive strength and 351% increase in flexural strength. Thermal stability of these composite foams was also found to be enhanced on the incorporation of kaolinite clay filler with an increase in 5% weight loss temperature (T_5%) from 192°C to 260°C. Furthermore, peak heat release rate (PHRR), total heat release (THR), smoke production rate (SPR), and total smoke release (TSR) were also found to decreased on the incorporation of mineral filler in the rigid polyurethane foam. So mineral fillers are ascertained as a potential filler to enhance the mechanical, thermal, and flame retardant behaviors of bio‐based rigid polyurethane foam composites.     

The comparison of properties of (rubber tree seed shell flour)‐filled polypropylene and high‐density polyethylene composites

The effect of varied rubber tree seed shell flour (RSSF) filler loadings on processing torque, mechanical, thermal, water absorption, and morphological properties of polypropylene (PP) and high‐density polyethylene (HDPE) composites has been studied. The addition of RSSF in the composites increased the stabilization torque in both PP‐ and HDPE‐based composites. Tensile strength, elongation at break, flexural strength, and impact strength show significant reduction when higher loading of RSSF was incorporated, while tensile modulus and flexural modulus were improved. The phenomenon was noted for both matrices, PP and HDPE, but HDPE‐based composites showed clear effects on the reduction of the mechanical properties compared with RSSF‐filled PP. Scanning electron microscopy of tensile fracture specimens revealed the degree of dispersion of RSSF filler in the matrices. At higher filler loadings, agglomerations and poor dispersion of RSSF particles were spotted, which induce the debonding mechanism of the system. Thermogravimetric analysis thermograms showed that both PP‐ and HDPE‐based composite systems with higher RSSF content have higher thermal stability, initial degradation temperature, degradation temperature, and total weight loss. Water absorption ability of the composites increases as the filler loading increases for both matrices. J. VINYL ADDIT. TECHNOL., 22:91–99, 2016. © 2014 Society of Plastics Engineers     

Effect of compatibilizers on water absorption kinetics of polypropylene/wood flour foamed composites

Polypropylene (PP)/wood flour foamed composites were prepared by taking PP:wood flour in the ratios of 100 : 0, 90 : 10, 80 : 20, 70 : 30, and 60 : 40 (w/w), with and without compatibilizers like maleic anhydride‐treated wood flour and maleic anhydride‐grafted PP (PPgMA). The foamed composite samples were employed for water swelling at 27°C, 70°C, and in steam. The absorption of water increased with increase in filler contents for all three‐temperature conditions. The maleic anhydride‐treated wood flour and PPgMA showed reduction in water swelling, and the best one was in case of the PPgMA‐foamed composites for respective conditions. Diffusion, sorption, and permeation coefficients were determined to study the absorption kinetics. FTIR spectra were also recorded for 30 wt % of filler loading for all the composites, which showed the effect of compatibilizers on reduction in water absorption in foamed PP/wood flour composites. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 101: 2530–2537, 2006     

An investigation on the mechanical and dynamic rheological properties of single and hybrid filler/polypropylene composites based on talc and calcium carbonate

Some results of experiments on the mechanical and rheological properties of mineral filled polypropylene were presented. Single filler and hybrid filler composites of talc and calcium carbonate (CaCO₃) were prepared in a co‐rotating twin‐screw extruder. The effect of filler type, filler content, and coupling agent on the mechanical and rheological properties of the polypropylene were studied. The coupling agent was maleic anhydride‐grafted polypropylene (PP‐g‐MA). It was found that the mechanical properties are affected by filler type, filler concentration, and the interaction between filler and matrix. The tensile strength of the composite is more affected by the talc while the impact strength is influenced mostly by CaCO₃ content. The elongation at break of PP/CaCO₃ composites was higher than that of PP/talc composites. The incorporation of coupling agent into PP/mineral filler composites increased the mechanical properties. Rheological properties indicated that the complex viscosity and storage modulus of talc filled samples were higher than those of calcium carbonate filled samples while the tan δ was lower. The rheological properties of hybrid‐filler filled sample were more affected by the talc than calcium carbonate. The PP‐g‐MA increased the complex viscosity and storage modulus of both single and hybrid composites. POLYM. COMPOS., 2009. © 2009 Society of Plastics Engineers     

Biofibers as reinforcing fillers in thermoplastic composites

Four biofiber materials were compared against wood flour for their ability to act as reinforcing fillers in melt-blended composites with polypropylene as the matrix polymer. The four materials were a waste wood composite (mixture of plywood, particleboard, and fiberboard), kenaf core, a waste jute–polyester composite panel, and waste newspaper. The composites were prepared either by extrusion or by blending in a high intensity thermokinetic mixer (K-mixer), and mechanical properties were determined on injection molded specimens. Although some property differences were observed compared to wood flour/polypropylene composites, it appeared that any of the four materials might substitute for wood flour if local supply and cost circumstances offered advantages. However, waste newspaper clearly provided the best balance of mechanical properties relative to the other three test materials or wood flour. Relative to wood flour, waste newspaper filler increased unnotched impact by over 30 percent and flexure and tensile strengths by about 25 percent.     

Crystallization of different polypropylene matrices in the presence of wood fillers

The increasing global energy crisis and ecological risks in recent years have led to the interest in lignocellulosic fillers reinforced polymer composites. In this study, the nucleation ability of pine wood in polypropylene (PP) matrices was studied by differential scanning calorimetry. PPs with different melt flow index values (in range 3.2–25 g/10 min.) were used as the polymer matrix. Moreover, a new technique of wood treatment using γ‐irradiation was used. The experimental results clearly show that the nucleation activity of the wood particles is strongly dependent on the rheological parameter (e.g., MFI) of PP matrix. The composites containing PP matrix with lower MFI exhibited higher degree of crystal conversion, lower half‐times of crystallization, and higher crystallization temperatures. Moreover, the applied γ‐irradiation of wood resulted in a negative effect on the crystallization rate of PP matrix and a distinct deterioration of the nucleation ability of wood surface. The interesting differences in nucleation activity of wood have been interpreted in the context of polymer chains length and relaxation times during crystallization. This article will spotlight the nucleating efficiency of filler, which is critical in polymer processing e.g., optimization of injection molding cycle time of composite materials. POLYM. COMPOS., 36:1813–1818, 2015. © 2014 Society of Plastics Engineers     

Effect of chemical treatments on the mechanical,flow, and morphological properties of talc‐ and kaolin‐filled polypropylene hybrid composites

This study was performed with commercially available phenyl trimethoxysilane (PTMS) and neoalkoxytitanate [i.e., neopentyl(diallyl)oxytri(dioctyl)phosphato titanate (LICA 12)] as coupling agents. PTMS and LICA 12 were used to treat talc and kaolin to compare their effects with untreated fillers upon incorporation into polypropylene (PP). Single‐filler PP composites (containing either talc or kaolin) and hybrid‐filler composites (containing a mix of both talc and kaolin) were compounded in a twin‐screw extruder and subsequently injection‐molded into dumbbells. The incorporation of PTMS and LICA 12 slightly decreased the tensile and flexural properties in terms of modulus and strength but increased the elongation at break for both single‐filler and hybrid‐filler composites. There was also a significant improvement in the impact strength of the composites, particularly those treated with LICA 12. The hybrid composites, through the synergistic coalescence of positive characteristics from talc and kaolin with the aid from chemical treatment provided an economically advantageous material with mechanical properties comparable to those of the single‐filler‐filled PP composites. Further investigations on flow and morphological properties were also done to correlate the mechanical properties of the single‐ and hybrid‐filler‐filled PP composites. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Water absorption and mechanical properties of PP/HIPS hybrid composites filled with wood flour

Water absorption and mechanical performance of the injection‐molded hybrid composites prepared from different ratios of two polymer blends (57 wt%), two compatibilizers (3 wt%), and two wood species (40 wt%) were investigated. The ratio of polypropylene and high‐impact polystyrene (HIPS) gradually increased in the blend (from 10 to 30 wt%). Styrene–ethylene–butylene–styreneblock copolymer and maleic anhydride‐grafted PP (MAPP) were used as compatibilizer (3 wt%). The shore D hardness of the PP/wood composites was improved by the incorporation of the HIPS. The HIPS/wood flour composites showed higher tensile modulus but lower tensile strength than the PP/wood composites. The water resistance of the PP/wood composites decreased with increasing HIPS content. POLYM. COMPOS., 38:863–869, 2017. © 2015 Society of Plastics Engineers     

Mechanical and Morphological Studies of Rubber Wood Sawdust-Filled UPR Composite Based on Recycled PET

Rubber wood sawdust fillers were mixed with unsaturated polyester matrix, which was prepared by recycling of PET waste from soft drink bottles, to prepare rubber wood sawdust/UPR composite. PET wastes were subjected to recycle by glycolysis and depolymerized to its monomer and dimmer. The glycolysed product was used to prepare unsaturated polyester resin. The FTIR analysis has been done on the resin and the glycolysed product. The resin then mixed with rubber wood sawdust fillers before and after alkali treatment with 10% NaOH. The effect of surface treatment and filler content on the mechanical properties and water absorption of the composite were studied. The tensile fractured surfaces of the composites were studied by Scanning Electron Microscopic (SEM) technique to investigate the interfacial bonding between the matrix and the filler. The results show that the tensile modulus increased with increasing filler contents. In addition, the results show that alkali treatment causes a better adhesion between rubber wood sawdust and UPR matrix and improves the mechanical properties.