Continuously extruded micro‐textured polypropylene films

The continuous extrusion of micro‐textured isotactic polypropylene (i‐PP) film and its tribological properties are reported. As analyzed by scanning electron microscopy, a rectangular‐semicircular micro‐patterned die successfully produced extruded cast‐films with hill‐like micro‐texture. Such films displayed static and kinetic coefficients of friction (COF_s and COF_k) values of 0.247 ± 0.028 and 0.245 ± 0.003, respectively, for a steel fixture sliding along the micro‐texture of the film. The equivalent COF_s and COF_k values for non‐textured (NT) films were 0.369 ± 0.036 and 0.340 ± 0.024, respectively, confirming that textured films displayed a reduction in COF of about 30%. For textured and NT films sliding on textured films, the COF_k values were even lower at 0.161 ± 0.013 and 0.113 ± 0.004, which represents about 20–40% reduction as compared with that for the NT‐NT counterparts. Films coated with a silicone lubricant displayed COF_s and COF_k values of 0.334 ± 0.042 and 0.099 ± 0.012, respectively, for NT films sliding over lubricated NT films, and 0.426 ± 0.031 and 0.063 ± 0.006, respectively, for textured films sliding over lubricated textured films. The COF_k values for textured/non‐lubricated films approach those of NT/lubricated films, indicating that micro‐textured polypropylene films may be used in environmentally sensitive applications where lubricants and fluorinated additives may not be used for reducing friction. POLYM. ENG. SCI., 54:2147–2154, 2014. © 2013 Society of Plastics Engineers     

Crystalline structure and thermodynamic analysis of ultra‐low diameter VGCF‐polypropylene nanocomposite monofilaments

Nanocomposites of VGCF reinforced polypropylene monofilaments were created using melt compounding extrusion. The monofilament diameter and VGCF loading were varied to characterize the effects of spinline stress and imposed confinement on material properties, including crystalline structure and thermodynamic behavior. A correlation was found between spinline stress, degree of confinement, depression of the melting temperature, and changes in crystallite dimensions and orientation. POLYM. COMPOS., 37:1641–1649, 2016. © 2014 Society of Plastics Engineers     

Optimum mixtures of stabilizers for polypropylene monofilaments and films

Conclusions The joint use of antioxidants of the phenolic type and SHA causes manifestation of an antagonistic action. By choosing optimum dosages of the stabilizers, this adverse effect can be reduced to a minimum.The fundamental possibility of replacing the imported stabilizers Tinuvin 327, Cyasorb UV-531, and Irganox 1010 by the domestic products diacetam 5, benzon OA, fenozan 23, and fenozan 28 in the production of PP and fibrous materials based on it has been demonstrated.In a complex of properties, the most effective mixed composition in articles based on PP is the one which contains diacetam 5 (0.2% by wt.) fenozan 23 (0.1% wt.), phosphite NF (0.2% by wt.), and DSTDP (0.2% by wt.).Translated from Khimicheskie Volokna, No. 5, pp. 10–12, September–October, 1984.     

Lemon essential oil desorption from polypropylene/talc nanocomposite films

A phenomenological analysis on desorption mechanism of lemon essential oil in semicrystalline polymer nanocomposites is performed. Films were made of polypropylene and talc nanoparticles obtained by blown extrusion were used as a case study due to the high complexity of sorption phenomena in such systems containing a semicrystalline polymer and nucleating particles. In this sense, a systematic analysis combining both morphological effects and intrinsic properties of each component was considered. Talc characteristics, e.g., morphology, surface chemistry, oil absorption properties, mean particle size and its distribution, and impurity presence, were considered in desorption analysis. Regarding semicrystalline matrix, morphological and crystalline changes induced by talc nanoparticles and processing were included in this study. Desorption of lemon essential oil from nanocomposite films with different talc concentrations (0, 1, and 5 wt%) which have distinctive and well characterized morphologies was evaluated through gravimetric and thermogravimetric analysis. Results show that polypropylene film has a desorption rate higher than nanocomposites containing 5 wt%, but lower than those with 1 wt% talc. This behavior is a consequence of the global crystallinity configuration changes produced by nanoparticle concentration and film obtaining process. It is revealed that simplified and conventional approaches that consider tortuosity as unique effect of particle presence in nanocomposite mass transport do not allow to comprehend the desorption mechanism involved in a complex system such as the semicrystalline polymer nanocomposites. The present study gives additional insight into the complex mechanism involved in desorption of strongly swelling oil in nanocomposite films based on semicrystalline polymers and mineral nucleating particles.     

Morphological studies on extruded films and filaments of polypropylene

In the present work, an attempt has been made to study the development of morphology during extrusion and uniaxial stretching of polypropylene (PP) films and filaments at corresponding conditions. Dies for extrusion of films and filaments were designed to achieve similar extrusion velocity and shear rates. Orientation in films and fibers of PP produced from these dies was determined by birefringence and wide-angle X-ray diffraction (WAXD). The degree of crystallinity was determined by density and WAXD. The superstructure developed during extrusion was studied in films by small-angle light scattering. It was inferred that films and fibers prepared under similar conditions would produce similar morphology. Hence, films can be characterized by optical techniques when it is difficult to study fibers. © 1994 John Wiley & Sons, Inc.     

Impact‐toughening mechanisms of calcium carbonate‐reinforced polypropylene nanocomposite

The impact fracture mechanisms of polypropylene (PP), containing 9.2 vol % of calcium carbonate (CaCO₃) nanoparticles, were investigated using optical microscopy and transmission electron microscopy. The incorporation of CaCO₃ nanoparticles reduces the size of spherulites and induces the formation of β‐phase crystallites, which leads to a more ductile PP matrix. Double‐notch four‐point bending (DN‐4PB) Charpy impact specimens and notched Izod impact specimens were utilized to study the fracture mechanism(s) responsible for the observed toughening effect. A detailed investigation reveals that the CaCO₃ nanoparticles act as stress concentrators to initiate massive crazes, followed by shear banding in PP matrix. These toughening mechanisms are responsible for the observed, improved impact strength. A comparison of the fracture mechanisms observed between DN‐4PB Charpy and Izod impact tests is also made to show the effectiveness of DN‐4PB for investigation of impact fracture mechanisms of polymeric systems. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 99: 3070–3076, 2006     

Kinetic study of polypropylene nanocomposite thermo‐oxidative degradation

Polypropylene (PP) has wide acceptance for use in many application areas. However, low thermal resistance complicates its general practice. The new approach in thermal stabilization of PP is based on the synthesis of PP nanocomposites. This paper discusses new advances in the study of the thermo‐oxidative degradation of PP nanocomposite. The observed results are interpreted by a proposed kinetic model, and the predominant role of the one‐dimensional diffusion type reaction. According to the kinetic analysis, PP nanocomposites had superior thermal and fireproof behaviour compared with neat PP. Copyright © 2005 Society of Chemical Industry     

Self‐reinforced polypropylene/LCP extruded strands and their moldings

Polypropylenes (PP) of various molecular weights were mixed with a thermotropic liquid crystal polymer (LCP) and strands were prepared by extrusion and stretching. The strands were subsequently pelletized and then injection molded at temperatures below the melting point of LCP. The mechanical properties and the morphology of the strands and injection‐molded specimens were investigated as a function of draw ratio, LCP concentration, and PP molecular weight. The results for strands show that an increase in the draw ratio, LCP concentration and matrix molecular weight in general enhance the modulus and tensile strength. However, the tensile properties of injection‐molded specimens are found to be reduced compared with those of the original strands, in particular at high LCP concentration. The morphology of LCP changes from spherical or ellipsoidal droplets to elongated fibrils in the strands as the draw ratio increases, but this aligned LCP fibrillar morphology was not transferred to the injection‐molded specimens because of the disorientation of fibrils during injection molding. Compatibilization of PP/LCP blends was also studied by using various polymers. Maleic anhydride and acrylic acid modified PPs improved the tensile properties modestly, but maleic anhydride modified EPDM reduced the tensile properties.     

Melt‐electrospun fibers obtained from polypropylene/poly(ethylene‐co‐vinyl alcohol)/polypropylene three‐layer films

Production of polypropylene (PP) nanofibers below 1 μm in average diameter is difficult with conventional melt‐spinning. A nozzle‐free melt‐type electrospinning (M‐ESP) system with a line‐like CO₂ laser beam melting device were used to produce PP nanofibers. To achieve the purpose, core [poly(ethylene‐co‐vinyl alcohol) (EVOH)]–clad (PP) nanofibers (average diameter, 0.88 μm) were fabricated from PP/EVOH/PP three‐layer films using the M‐ESP. The core–clad structure was formed by a wrapping phenomenon caused by the difference in the melt flow rates (MFRs) of PP and EVOH melts. Hollow PP nanofibers were obtained from the core–clad nanofibers by extraction of EVOH. Nanofiber diameter and hollow wall thickness could be altered by changing the MFR of the PP melt. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46393.     

Co‐extruded polymeric films for gas separation membranes

In recent years, gas separation has become an important step in many production process streams and part of final products. Through the use of melt co‐extrusion and subsequent orientation methods, gas separation membranes were produced entirely without the use of solvents, upon which current methods are highly dependent. Symmetric three layer membranes were produced using poly(ether‐block‐amide) (PEBA) copolymers, which serve as a selective material that exhibits a high CO₂ permeability relative to O₂. Thin layers of PEBA are supported by a polypropylene (PP) layer that is made porous through the use of two methods: (1) inorganic fillers or (2) crystal phase transformation. Two membrane systems, PEBA/(PP + CaCO₃) and PEBA/β‐PP, maintained a high CO₂/O₂ selectivity while exhibiting reduced permeability. Incorporation of an annealing step either before or after orientation improves the membrane gas flux by 50 to 100%. The improvement in gas flux was a result of either elimination of strain induced crystallinity, which increases the selective layer permeability, or improvement of the PP crystal structure, which may increase pore size in the porous support layer. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 39765.     

Mechanical performance of re‐extruded and aged graphene/polypropylene nanocomposites

In the present research polypropylene/expanded graphite (PP/ExpG) and polypropylene/graphene nanoplatelet (PP/GNP) composites were prepared by melt blending and their morphology and tensile properties were investigated. Although both reinforcements improved the elastic modulus of PP, PP/GNP composite presented better dispersion of the nanofiller in the polymer matrix and it was selected for further re‐extrusion and ageing experiments. The re‐extrusion affected the content of crystal phases of PP in pure PP and in its nanocomposite with GNP and increased their elastic modulus. The ageing of one and five times re‐extruded PP caused an increase of the β‐crystal phase and the formation of voids in the cross‐section. GNPs seem to protect the PP matrix from ageing as in Fourier transform IR spectra of PP/GNP nanocomposite, both one and five times extruded, the peak corresponding to carbonyl degradation products of PP was barely visible. The tensile properties of aged nanocomposites, one and five times re‐extruded, were similar to those of the corresponding non‐aged composites, whereas in aged PP the tensile strength and strain decreased significantly compared to non‐aged PP. The anti‐ageing effect of graphene can prolong the life of the PP matrix. © 2017 Society of Chemical Industry     

Zeolite A‐polypropylene and silver‐zeolite A‐polypropylene composite films for antibacterial and breathable applications

Polypropylene (PP) composite films were successfully prepared using melt blending by directly mixing PP pellets with zeolite A or silver‐zeolite A powder and then blowing. All the prepared films were characterized in terms of their physical, mechanical, optical, and gas permeability properties. The structure of each composite film was similar to that of the pure PP film. The crystallinity and glossy quality of the composite films were increased by the addition of silver, zeolite, and maleic anhydride grafted PP (PP‐g ‐MA). The composite PP film with zeolite A and PP‐g ‐MA exhibited a level of oxygen and carbon dioxide permeation (6438 and 15,087 cc m^?2 day^?1 atm^?1, respectively). Finally, all the films were evaluated for their antibacterial activity and fruit packaging applications. Silver‐zeolite A‐PP composite films exhibited a bactericidal activity of 79% against Staphylococcus aureus and 52% against Escherichia coli , while the zeolite A‐PP film could extend the shelf‐life of bananas for over a week. © 2017 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2017 , 134 , 45450.     

Air‐hole properties of calcite‐filled polypropylene copolymer films

This work was designed to study the effects of inorganic calcite powder on structurally different copolymer [poly(propylene‐co‐ethylene)] and terpolymer [poly (propylene‐co‐ethylene‐co‐1‐butene)] matrices and the possibility of making a suitable porous composite film. The yield stress of the composites did not improve, but the modulus increased gradually with the filler loading. The theoretical and experimental modulus and yield stress of the composites provided evidence of filler and polymer adhesion behavior. The impact strength showed little enhancement up to a 20 wt % loading for the poly(propylene‐co‐ethylene‐co‐1‐butene) system. The number‐average, weight‐average, and z‐average air‐hole diameters were compared with respect to the draw ratio as well as the calcite loading. The morphology of a micromechanically deformed composite, studied with an image analyzer, revealed that the aspect ratio and area of the air holes increased linearly as a function of the draw ratio, but the change in the aspect ratio upon filler loading was not remarkable. A suitable loading of a filler up to 30 wt % was good for controlling the porosity in the composite films. © 2008 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Preparation of extruded melt‐mixed polypropylene/montmorillonite nanocomposites with inline monitoring

This article advances the use of an inline optical detector to monitor the disaggregation of the montmorillonite (MMT) clay tactoids during the preparation of polypropylene (PP)/MMT nanocomposites via polymer melt compounding. During the exfoliation of the tactoids their size are reduced below the minimum particle size to produce light extinction and so, the signal of the inline detector reduces as the nanosize composite is formed. The measurement is done at the transient state with the MMT clay added as a pulse with constant weight into the PP extrusion melt flow and followed by the optical detector. The data comes out as the common residence time distribution curves having its maximum intensity related to the tactoids average particle size, keeping all other variables constants. The light extinction was measured for composites with different clays (Cloisite® 15A, 30B, Na⁺, and Sintered 20A) using the same PP grafted with maleic anhydride compatibilizer. The dissaglomeration/exfoliation efficiency increases as: ‘‘Sintered 20A’’ < ‘‘Na+ clay’’ < ‘‘organo‐modified clay’’ < ‘‘organo‐modified clay + compatibilizer’’. The best result is obtained using Cloisite® 15A and Cloisite® 20A following the expected reduction of the particle size obtained during a nanocomposite melt processing. POLYM. ENG. SCI., 2010. © 2009 Society of Plastics Engineers     

Polypropylene/styrene‐ethylene‐butylene‐styrene thermoplastic elastomer nanocomposite films

Nanocomposite (polypropylene/styrene‐ethylene‐butylene‐styrene/organoclay) films were sheet‐extruded with differing clay concentrations. Blends were compounded using a high shear single screw reciprocating kneader. Results demonstrated that higher clay content increased the Shore A hardness of the films but induced a significant improvement in both O₂ and CO₂ barrier performance. J. VINYL ADDIT. TECHNOL., 13:46–52, 2007. © 2007 Society of Plastics Engineers.     

ABS nanocomposite films based on functionalized‐graphene sheets

Acrylonitrile‐butadiene‐styrene (ABS)/functionalized‐graphene nanocomposites were synthesized using the solution‐blending method in chloroform. A dispersion of graphite oxide was added to a solution of the ammonium salt of octadecylamine (C18) to form octadecylamine‐graphene (C18‐graphene), which was then used as a functionalized graphene in the preparation of ABS nanocomposite films. ABS nanocomposite films with different C18‐graphene contents (0–3 wt %) were compared in terms of their thermomechanical properties and morphology. Despite the relatively low C18‐graphene loadings studied, the nanocomposite films exhibited greatly improved thermomechanical properties compared with pure ABS. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Transparent low‐density polyethylene/starch nanocomposite films

Low‐density polyethylene (LDPE)/starch nanocomposite films were prepared by melt extrusion process. The first step includes the preparation of starch–clay nanocomposite by solution intercalation method. The resultant product was then melt mixed with the main matrix, which is LDPE. Maleic anhydride‐grafted polyethylene (MAgPE), produced by reactive extrusion, was used as a compatibilizer between starch and LDPE phases. The effects of using compatibilizer, clay, and plasticizers on physico‐mechanical properties were investigated. The results indicated that the initial intercalation reaction of clay layers with starch molecules, the conversion of starch into thermoplastic starch (TPS) by plasticizers, and using MAgPE as a compatibilizer provided uniform distribution of both starch particles and clay layers, without any need of alkyl ammonium treatment, in LDPE matrix. The nanocomposite films exhibited better tensile properties compared to clay‐free ones. In addition, the transparency of LDPE film did not significantly change in the presence of TPS and clay particles. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Oriented monofilaments from blends of poly(ethylene terephthalate) and polypropylene

Poly(ethylene terephthalate) and polypropylene are considered, to be incompatible by the usual criteria for polymer blends. Sheath/core filaments of these polymers could not be oriented because of poor adhesion of the base polymers. Melt blends of the two polymers with 30 and 50 weight percent polypropylene produced useful, oriented monofilaments. Tensile and dynamic mechanical properties of these filaments indicate that the structures consist of interlocked microfibrillar domains of the polyester and polyolefim. The glass transition region of poly(ethylene terephthalate) is not affected by admixture with polypropylene. A fine mutual dispersion of the two polymers was possible because the melt viscosities of the ingredients were reasonably well matched under the conditions of mixing. The melt viscosity and elasticity of blends were lower than those of either component as expected if the two polymers are immiscible. Monofilament extrusion and melt flow measurements were made with a one-half inch single screw extruder.     

Influence of initial mixing methods on melt‐extruded single‐walled carbon nanotube–polypropylene nanocomposites

We report the first direct comparison of melt‐extruded polypropylene–single‐walled carbon nanotube (PP/SWNT) nanocomposites prepared by three different initial mixing methods. The standard deviation of the G‐band intensity obtained using Raman mapping was found to be the best measure of dispersion uniformity in the extruded composites, and dispersion uniformity was found to generally correlate with rheological and thermal properties. For all three initial mixing methods, both unmodified and sidewall‐functionalized purified SWNTs were evaluated. Surprisingly, in all cases, dodecylated SWNTs prepared using the reductive alkylation method were less uniformly dispersed in the final composite than the unmodified SWNTs. The simplest process, dry blending, resulted in poor nanotube dispersion and only polymer crystallization was significantly affected by the presence of the nanotubes. A slightly more complex rotary evaporation process resulted in significantly more uniform dispersion and significant changes in rheological properties, polymer crystallization, and thermal stability. The most elaborate process tested, hot coagulation, enabled the most uniform dispersion and the greatest change in properties but also resulted in some polymer degradation. POLYM. ENG. SCI., 50:1831–1842, 2010. © 2010 Society of Plastics Engineers