Polypropylene‐dispersed domain as potential nucleating agent in PS and PMMA solid‐state foaming

The potential of using dispersive domains in a polymer blend as a bubble nucleating agent was investigated by exploiting its high dispersibility in a matrix polymer in the molten state and its immiscibility in the solid state. In this experiments, polypropylene (PP) was used as the nucleating agent in polystyrene (PS) and poly(methyl methacrylate) (PMMA) foams at the weight fraction of 10, 20, and 30 wt %. PP creates highly dispersed domains in PS and PMMA matrices during the extrusion processing. The high diffusivity of the physical foaming agent, i.e., CO₂ in PP, and the high interfacial tension of PP with PS and PMMA could be beneficial for providing preferential bubble nucleation sites. The experimental results of the pressure quench solid‐state foaming of PS/PP and PMMA/PP blends verified that the dispersed PP could successfully increase the cell density over 10⁶ cells/cm³ for PS/PP and 10⁷ cells/cm³ for PMMA/PP blend and reduce the cell size to 24 μm for PS/PP and 9 μm for PMMA/PP blends foams. The higher interfacial tension between PP and the matrix polymer created a unique cell morphology where dispersed PP particles were trapped inside cells in the foam. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Effect of flexibility of ethylene vinyl acetate and crystallization of polypropylene on the mechanical properties of i‐PP/EVA blends

Polymer blend technology has been widely used for the past several years for the modification or enhancement of mechanical properties of polymers to obtain an overall balance of properties over those of the constituents. Despite its interesting mechanical and thermal properties, the impact strength of polypropylene leaves wide scope for improvement. A series of blends of ethylene vinyl acetate (EVA) copolymer with an impact grade of isotactic polypropylene (i‐PP) were prepared by single screw extrusion at 0–0.32 volume fraction of the dispersed phase. The mechanical properties such as tensile behavior, elongation‐at‐break, and impact strength of these blends systems as well as crystallinity were evaluated. Crystallinity data have been used in greater depth to support the mechanical properties. Differential scanning calorimetry studies conducted to study the modification in crystallinity of the crystalline component, i‐PP, of the blend revealed that the rubber component of the blend enhanced the crystallinity of i‐PP phase by providing sites for nucleation. Tensile modulus and strength decreased while the impact strength and breaking elongation enhanced with blending elastomer concentration. The improved properties of these PP/EVA blends are encouraging for carrying out further work on this system (composites) and suggest potential high impact strength applications for PP. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Thermal behavior and morphological and rheological properties of polypropylene and novel elastomeric ethylene copolymer blends

The thermal behavior including melting and crystallization behavior and morphological and rheological properties of the blends based on an isotactic polypropylene and a novel maleated elastomeric ethylene copolymer were investigated in this work. The addition of an elastomer to polypropylene (PP) was found not to change the PP crystalline structure significantly when cooled quickly from the melt. On recrystallization at a lower cooling rate, the elastomer promotes the formation of β?pseudohexagonal PP in PP‐rich blends. In elastomer‐rich compositions, heterogeneous nucleation is hindered and homogeneous nucleation takes place. These phenomena are revealed by morphology observation: that, with increasing of the elastomer content, the system undergoes PP continuous, dual‐phase continuity and PP‐dispersed morphologies. The blend viscosity at a low shear rate range increases continuously with increasing elastomer content and shows positive deviations from the additivity rule. In the terminal zone, the dynamic storage modulus of the blends shows positive deviation from the simple mixing rule and the maximum deviation lies in the composition range of dual‐phase continuity which could be caused by a large increase in the interfacial tension. The Cox–Merz rule does not hold for the blends because of the two‐phase heterogeneous structure and its variation in steady and oscillatory shear flow. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 86: 3430–3439, 2002     

The effect of viscosity of polyethylene on the evolution of phase structure during the mixing of polypropylene/EPDM elastomer/polyethylene blends

The dependences of phase structure and notch impact strength on conditions of mixing have been compared for the binary blend PP/EPDM and for two ternary blends PP/EPDM/PE possessing different viscosities of polyethylene. At low rates and short times of mixing a phase structure with pronounced inhomogeneities (particles of the dispersed phase having diameters of tens μm) is formed in all blends. Conditions of mixing needed for the formation of a homogeneous phase structure (with particles having diameters of several μm) depend on the average viscosity of the components forming the inclusions (EPDM elastomer or EPDM elastomer/polyethylene). Depending on the conditions of mixing and on the rheological properties of components, substitution of one part of the EPDM elastomer with PE may lead to an increase or decrease in the impact strength of the final blend.     

Nanoscale Cellular Foams from a Poly(propylene)‐Rubber Blend

Plastic foams with nano/micro‐scale cellular structures were prepared from poly(propylene)/thermoplastic polystyrene elastomer (PP/TPS) systems, specifically the copolymer blends PP/hydrogenated polystyrene‐block‐polybutadiene‐block‐polystyrene rubber and PP/hydrogenated polystyrene‐block‐polyisoprene‐block‐polystyrene. These PP/TPS systems have the unique characteristic that the elastomer domain can be highly dispersed and oriented in the machine direction by changing the draw‐down ratio in the extrusion process. A temperature‐quench batch physical foaming method was used to foam these two systems with CO₂. The cell size and location were highly controlled in the dispersed elastomer domains by exploiting the differences in CO₂ solubility, diffusivity, and viscoelasticity between the elastomer domains and the PP matrix. The average cell diameter of the PP/TPS blend foams was controlled to be 200–400 nm on the finest level by manipulating the PP/rubber ratio, the draw‐down ratio of extrusion and the foaming temperature. Furthermore, the cellular structure could be highly oriented in one direction by using the highly‐oriented elastomer domains in the polymer blend morphology as a template for foaming.

     

Rheological,thermal, and morphological properties of blends based on poly(propylene), ethylene propylene rubber,and ethylene-1-octene copolymer that could result from end of life vehicles: Effect of maleic anhydride grafted poly(propylene)

The objective of this work is to study the properties of blends that could result from the recycling of end-of-life vehicles (ELV). While ethylene propylene rubber (EPR) and ethylene propylene diene monomer (EPDM) have been used extensively as elastomeric additives in poly(propylene) (PP), they can be substituted by ethylene-1-octene copolymer (EOC). As a consequence, the matter resulting from the sorting of ELV might be more complex and made of PP, EPR, and EOC. The effect of incorporating EOC [that is a polyethylene elastomer (PEE)] and maleic anhydride grafted polypropylene (PP-g-MAH) on the rheological, thermal, and morphological properties of PP/EPR blends has been investigated. Blends of various compositions (with and without compatibilizer) were prepared using a corotating twin-screw extruder. The results were compared to the ones presented by a commercial (PP/EPR) blend. The EPR phase is dispersed in the form of spherical particles in (PP/EPR). The EOC phase is dispersed in the form of aggregated particles. Dynamic viscoelastic and differential scanning calorimetry properties of (PP/EPR)/EOC blends shows the incompatibility of the components even in presence of PP-g-MAH copolymer. POLYM. ENG. SCI., 47:1009–1015, 2007. © 2007 Society of Plastics Engineers     

Effect of branched PP content on the physical properties and cell growth during foaming of TPOs

Linear/branched PP blends at various ratios were used as the matrix for thermoplastic olefin (TPO) compounds, containing an ethylene–octene copolymer dispersed phase. A detailed investigation of the physical properties of these blends revealed that addition of branched PP (BPP) resulted in improved stiffness and flexural properties. Given that the phase morphology of the blends and the interfacial tension between their components remained virtually unaffected, these improvements are attributed to the higher stiffness of the BPP‐containing matrices. Talc‐filled TPOs containing branched PPs exhibited further improvements in the stiffness and flexural properties. An investigation into the bubble growth process during foaming using a batch foaming simulation system revealed that the presence of BPP resulted in a slight delay in cell nucleation, whereas the rate of bubble growth was not significantly altered. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Linear viscoelastic properties of olefinic thermoplastic elastomer blends: melt state properties

The linear viscoelastic properties of two types of olefinic thermoplastic elastomer blends were studied using dynamic rheology. The first type consists of a blend of PP, SEBS and oil and has a co-continuous morphology. The second type consists of vulcanised EPDM particles dispersed in a PP matrix. The dynamic rheological behaviour of the blends is a weighted contribution of the properties of the two individual phases. In both blend types, the storage modulus at low frequencies can be correlated to the properties and morphology of the elastomer phase. With increasing PP or oil content in the blend the value of the modulus at low frequencies are reduced. The mechanical models of Coran and Veenstra are able to describe the dynamic moduli. An additional parameter was included to determine the oil concentration in the two phases. The model parameters are correlated to the composition and the morphology.     

Multiple crystallization behaviour of polypropylene/thermoplastic rubber blends and its use in assessing blend morphology

Blends of polypropylene (PP) and thermoplastic rubber (TR) have been studied using differential scanning calorimetry (d.s.c.). For blends with PP as the dispersed phase, a multiple crystallization behaviour was observed; two low-temperature crystallization exotherms at about 75° and 45°C were found in addition to the amount PP crystallization exotherm at about 106°C. The occurrence of the crystallization exotherm at 75°C was explained by a homogeneous nucleation mechanism. It is shown that this multiple crystallization behaviour can be utilized in assessing the morphology of the blends, such as the type of the dispersion (phase continuity) and the degree of the dispersion (PP particle size). The d.s.c. approach is not necessarily restricted to PP/TR blend systems, but can also be applied to other blend systems.     

Effect of nanosilica on the co-continuous morphology of polypropylene/polyolefin elastomer blends

This paper reports the effect of nanosilica (SiO₂) on the morphology of co-continuous immiscible polypropylene (PP)/polyolefin elastomer (POE) blends. The unfilled blends display phase inversion and a co-continuous structure at a ratio of 50/50 PP/POE by weight. Upon addition of SiO₂ in the presence of maleated PP compatibilizer a finer structure, consisting of elongated POE particles dispersed within the PP phase is obtained. This transformation is associated to the presence of finely dispersed SiO₂ particles that are localized exclusively within the PP matrix. The impact properties, flexural and Young's moduli of the blends increase significantly, pointing to a synergistic effect arising from the presence of the reinforced PP phase, containing high amounts of the finely dispersed elastomeric phase.     

Batch Foam Processing of Polypropylene/Polydimethylsiloxane Blends

Batch foaming processes were employed to prepare plastic foams from polypropylene (PP)/polydimethylsiloxane (PDMS) blends. Various amounts of PDMS were added to a PP matrix, and the resulting blends were batch foamed at different saturation pressures using carbon dioxide (CO₂) as the blowing agent. Ultimately, the blend foams exhibited better cell morphologies and higher cell densities in comparison with those prepared from PP alone. The increased solubility of CO₂ in PDMS made it as a CO₂ reservoir to induce more nucleation. When the PDMS content exceeded a certain level, however, it exerted a negative influence on cell density. Moreover, as the saturation pressure was raised, the cell density of the blend foams increased significantly. It was also noted that the addition of PDMS to the PP matrix generated some very small cells in the larger cell walls.     

Effect of filler partitioning on the mechanical properties of TPO/nanosilica composites

Nanosilica (SiO₂) is used as a reinforcing filler in PP/elastomer thermoplastic polyolefin (TPO) blends containing ethylene‐octene polyolefin elastomer (POE), ethylene‐propylene rubber (EPR), and maleated EPR. The localization and dispersion of the filler are controlled by adding maleated derivatives to the matrix or the dispersed phase. A separated morphology, consisting of SiO₂ residing in the PP matrix, is necessary to achieve improvements in modulus. Filled TPOs containing POE have the best performance and exhibit improved moduli while retaining high values of elongation. J. VINYL ADDIT. TECHNOL., 13:147–150, 2007. © 2007 Society of Plastics Engineers     

Microcellular foam of polymer blends of HDPE/PP and their composites with wood fiber

In this study, the effects of batch processing conditions (foaming time and temperature) and blend composition as well as the effect of incorporating wood fiber into the blends on the crystallinity, sorption behavior of CO₂, void fraction, and cellular morphology of microcellular foamed high‐density polyethylene (HDPE)/polypropylene (PP) blends and their composites with wood fiber were studied. Blending decreased the crystallinity of HDPE and PP and facilitated microcellular foam production in blend materials. The void fraction was strongly dependent on the processing conditions and on blend composition. Foamed samples with a high void fraction were not always microcellular. The addition of wood fiber inhibited microcellular foaming. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 2842–2850, 2003     

Effect of the high‐density polyethylene melt index on the microcellular foaming of high‐density polyethylene/polypropylene blends

The effect of high‐density polyethylene (HDPE)/polypropylene (PP) blending on the crystallinity as a function of the HDPE melt index was studied. The melting temperature and total amount of crystallinity in the HDPE/PP blends were lower than those of the pure polymers, regardless of the blend composition and melt index. The effects of the melt index, blending, and foaming conditions (foaming temperature and foaming time) on the void fractions of HDPEs of various melt indices and HDPE/PP blends were also investigated. The void fraction was strongly dependent on the foaming time, foaming temperature, and blend composition as well as the melt index of HDPE. The void fraction of the foamed 30:70 HDPE/PP blend was always higher than that of the foamed 50:50 HDPE/PP blend, regardless of the melt index. The microcellular structure could be greatly improved with a suitable ratio of HDPE to PP and with foaming above the melting temperature for long enough; however, using high‐melt‐index HDPE in the HDPE/PP blends had a deleterious effect on both the void fraction and cell morphology of the blends. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 364–371, 2004     

Rheology,morphology, and mechanical properties of reactive compatibilized polypropylene/polystyrene blends via Friedel–Crafts alkylation reaction in the presence of clay

Attempts were made to study the effect of reactive compatibilization via Friedel–Crafts alkylation reaction, using AlCl₃ as a catalyst, on rheology, morphology, and mechanical properties of polypropylene/polystyrene ( PP/PS) blends in the presence of an organoclay (Cloisite 15A). During the reactive compatibilization process, PS showed much more degradation than that of PP in the presence of AlCl₃. It was found that the effect of generation of PP‐g‐PS copolymer at the interface of the PP/PS blend dominates the effects of degradation of PS and PP phases, which manifested itself by increased toughness as well as uniform dispersion of the dispersed PS particles in the PP matrix. Generation of PP‐g‐PS copolymer was confirmed by using Fourier‐transform infrared analysis. By using rheological and X‐ray diffraction analyses, it was shown that the clay had higher affinity to PS than that of PP. It was also shown that the clay located at the interface of PP and PS phases, leading to increased relaxation time of the deformed PS dispersed particles, exhibited higher dispersion in PP/PS blend, which resulted in higher ductility of the blend. By using the results of rheological studies, it was concluded that during reactive compatibilization of the blend nanocomposite, the clay migrated into the dispersed PS phase, which was confirmed by scanning electron microscopy analysis. It was demonstrated that the rheological studies have a reliable sensitivity to the clay partitioning and phase morphology of the studied blends and blend nanocomposites . J. VINYL ADDIT. TECHNOL., 24:18–26, 2018. © 2015 Society of Plastics Engineers     

Selective crosslinking in polymer blends. II. Its effect on impact strength and other mechanical properties of polypropylene/unsaturated elastomer blends

The effect of selective crosslinking of the unsaturated elastomer particles in polypropylene (PP) matrix was investigated. The crosslink system comprised N,N′-m-phenylene-bismaleimide and 6-ethoxy-2,2,4-trimethyl-1,2-dihydroqinoline or polymerized-(2,2,4-trimethyl-1,2-dihydroquinoline). The system, which produces only carbon radicals, crosslinks the elastomer particles selectively without causing excessive degradation of the PP matrix. The reaction was carried out under a dynamic crosslinking process using a twin extruder on PP/EPDM, PP/SBS, and PP/SIS blends, all of which comprised 80 wt % of PP and 20 wt % of the elastomer. After the crosslinking, the impact strength of the blends increased. Especially remarkable increase is obtained at 23°C where PP is above its T_g. The increase of interfacial adhesion caused by production of PP/elastomer graft copolymer at the interface is considered to be the most important factor in the improvement. It permits the interactions of the stress concentrate zone developed at the elastomer particles and causes shear yielding of the PP matrix. Impact fracture energy absorption can be thus changed by adjusting the degree of the interfacial adhesion even at essentially the same morphology. The crosslinked elastomer particles also play the role of a nucleation agent. The selective cross-linking of the elastomer particles in PP/elastomer blends is demonstrated to be an excellent technique to produce a high-impact, high-modulus PP. © 1994 John Wiley & Sons, Inc.     

Effect of the mixing conditions on the phase structure of PP/PS blends

The effect of the rate and time of mixing in a batch mixer on the phase structure of polypropylene/polystyrene (PP/PS) blends with various rheological properties of the components was studied. Regions with substantially different average sizes of the dispersed particles were found in the studied blends. Differences between the average size of the particles in individual regions of the samples persist in all blends and mixing conditions under study. No dependence of the average particle size on the rate of mixing has been obtained for the PP/PS (75/25) blends. On the other hand, decrease of the average particle size with increasing rate of mixing has been found for the PP/PS (95/5) blend. These results are discussed as a consequence of the competition between the breakup and coalescence of the dispersed particles. © 1996 John Wiley & Sons, Inc.     

Polypropylene-elastomer (TPO) nanocomposites: 2. Room temperature Izod impact strength and tensile properties

Room temperature Izod impact strength was determined for polypropylene (PP)/ethylene-co-octene elastomer (EOR) blends and nanocomposites, containing organoclays based on montmorillonite (MMT), at fixed elastomer content of 30 wt% and 0-7 wt% MMT. A ratio of maleated polypropylene, PP-g-MA to organoclay of unity was used as a compatibilizer in the nanocomposites. The organoclay serves to reduce the size of the EOR dispersed phase particles and facilitates toughening. The Izod impact strength is also influenced by the molecular weight of PP, elastomer octene content, elastomer MFI in addition to MMT content. Nanocomposites based on a low molecular weight polypropylene (L-PP) containing a higher octene content elastomer showed higher impact strength at lower MMT contents compared to those based on a low octene content elastomer. The effect of elastomer octene content on impact strength of high molecular weight polypropylene (H-PP) nanocomposites is not so significant. Elastomers having a melt flow index (MFI) in the range of 0.5-1.0 showed significant improvement in the impact strength of L-PP based nanocomposites. Most H-PP/EOR blends gave ‘super-tough’ materials without MMT and maintain this toughness in the presence of MMT. The critical elastomer particle size below which the toughness is observed is reduced by decreasing the octene content of the elastomer. For the similar elastomer particle sizes in nanocomposites, the impact strength varies as H-PP > M-PP > L-PP. The tensile modulus and yield strength improved with increasing MMT content; however, elongation at break was reduced. The extruder-made TPO showed a good-balance of properties in the presence of MMT compared to reactor-made TPO having similar modulus and elastomer content.     

Study of the modification of the properties of (PP/EPR) blends with a view to preserving natural resources when elaborating new formulation and recycling polymers

The aim of the present work is to study how CaCO₃, very abundant on earth, can be blended with polypropylene/ethylene propylene rubber (PP/EPR) either to preserve natural resources when elaborating virgin formulations or to simulate mixtures of waste made of CaCO₃ filled PP with PP/EPR which could result from end-of-life-vehicles (ELV). The article focuses on the studies of PP/EPR blends, used in the manufacture of automobile fenders, in the presence of nano-CaCO₃ and compatibilizers. Blends of various compositions (with and without compatibilizer and nanoparticles) were prepared using a corotating twin-screw extruder. The results were compared with the ones presented by a commercial (PP/EPR) blend. The experiments included mechanical tests, differential scanning calorimetry, scanning electron microscopy, and dynamic mechanical analysis experiments. The presence of the compatibilizers in the (PP/EPR) blends decreases the size of elastomer particles, improves the adherence to the interface and improves the mechanical properties. The nano-CaCO₃ would also seem to act as a nucleating agent in the PP/EPR matrix; it increases the cristallinity and the Young modulus of the blends. POLYM. COMPOS., 2009. © 2008 Society of Plastics Engineers     

Morphological and rheological footprints corroborating optimum foam processability of PP/ethylene acrylic elastomer blend

The focus of the present work is optimization of microcellular foam processing of Polypropylene (PP)/ethylene acrylic elastomer blends, through design of experiment approach using Taguchi technique and establishing correlation among foamability, morphological, and rheological parameters of blends. PP and elastomer are melt blended in a twin screw extruder and thereafter foaming parameter optimization is carried out using Taguchi method followed by analysis of variance (ANOVA) for batch foaming setup. Scanning electron microscope reveals development of submicron elastomer domains, which increase with the elastomer content. Further, complex viscosity and van Grup–Palmen plots are found to have a vital role in attaining cellular morphology development in blends. From Taguchi and ANOVA analysis it is established that foaming temperature has a great influence and major contribution on foamability. Blends with low elastomer content are optimized for better foamability using statistical approach and proved to be consistent with the morphological and rheological outcomes. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46322.