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     

Characterization of the free volume in high‐impact polystyrene/polypropylene and high‐impact polystyrene/high‐density polyethylene blends probed by positron annihilation spectroscopy

The free‐volume properties of high‐impact polystyrene (HIPS)/polypropylene (PP) and HIPS/high‐density polyethylene (HDPE) blends were investigated by means of positron annihilation lifetime spectroscopy (PALS). The measured results show that the free‐volume holes in the semicrystalline polymers, such as PP and HDPE, were not large enough to accommodate the branched chains and the end groups of the macromolecular chains in HIPS to produce favorable interactions between the semicrystalline polymers and the HIPS polymer in these blends; thus immiscible blends were formed. The weak interaction between two dissimilar polymer molecules only took place in the regions between two amorphous phases. In addition, the observed negative deviations of the longest lifetime intensity and the free‐volume fraction were attributed to the influence of the interfacial polarization during PALS measurement. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 1507–1514, 2003     

Studies on blends of high‐density polyethylene and polypropylene produced by oscillating shear stress field

Tensile strength and morphology of blends of high‐density polyethylene (HDPE) and polypropylene (PP) obtained by oscillating packing injection molding were investigated via Universal Testing Machine, DSC, and SAXS. Tensile strength is greatly enhanced from 24.5 MPa to more than 90 MPa for pure HDPE and for blends with PP content less than 10 wt %. There exists a sharp decrease of tensile strength when PP content is more than 10 wt %. The shear‐induced morphologies with core in the center, oriented zone surrounding the core and skin layer are observed in the cross‐section areas of the samples. Interestingly, a sharp decrease of oriented zone is seen when PP content is more than 10 wt %, associated with the sharp decrease of tensile strength. DSC result shows double melting peaks with a high‐temperature melting peak that is not present in the endotherm obtained from the central core and obtained from the samples by static packing injection molding, which indicates the existence of shish‐kebab structure in the oriented zone. However, there is no difference of crystallinity between the samples by oscillating and by static packing injection molding. SAXS was used to analyze the complicated morphologies induced by shear stress, and results show that the crystal thickness could be greatly increased under shear stress. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 86: 58–63, 2002     

Structure and properties of polypropylene/low‐density polyethylene blends grafted with itaconic acid in the course of reactive extrusion

This study was concerned with the structural features and mechanical properties of polypropylene (PP)/low‐density polyethylene (LDPE) blends, which after compounding were modified by the free‐radical grafting of itaconic acid (IA) to produce [PP/LDPE]‐g‐IA in the course of reactive extrusion. To analyze the structural features of the [PP/LDPE]‐g‐IA systems, differential scanning calorimetry and relaxation spectrometry techniques were used. The data were indicative of the incompatibility of PP and LDPE in the [PP/LDPE]‐g‐IA systems on the level of crystalline phases; however, favorable interactions were observed within the amorphous phases of the polymers. Because of these interactions, the crystallization temperature of PP increased by 5–11°C, and that of LDPE increased by 1.3–2.7°C. The rapprochement of their glass‐transition temperatures was observed. The single β‐relaxation peak for the [PP/LDPE]‐g‐IA systems showed that compatibility on the level of structural units was responsible for β relaxation in the homopolymers used. Variations in the ratios of the polymers in the [PP/LDPE]‐g‐IA systems led to both nonadditive and complex changes in the viscoelastic properties as well as mechanical characteristics for the composites. Additions of up to 5 wt % PP strengthened the [PP/LDPE]‐g‐IA blended systems between the glass‐transition temperatures of LDPE and PP. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 1746–1754, 2006     

Modeling of solid–liquid equilibria for polyethylene and polypropylene solutions with equations of state

We modeled solid–liquid equilibria (SLEs) in polyethylene and polypropylene solutions with a Soave–Redlich–Kwong (SRK) cubic equation of state (EOS) and a perturbed‐chain statistical associating fluid theory (PC‐SAFT) EOS. Two types of mixing rules were used with SRK EOS: The Wong–Sandler mixing rule and the linear combination of the Vidal and Michelsen mixing rules (LCVM), both of which incorporated the Bogdanic and Vidal activity coefficient model. The performance of these models was evaluated with atmospheric‐pressure and high‐pressure experimental SLE data obtained from literature. The basic SLE equation was solved for the equilibrium melting temperature instead of for the composition. The binary interaction parameters of SRK and PC‐SAFT EOS were estimated to best describe the experimental equilibrium behavior of 20 different polymer–solvent systems at atmospheric pressure and 31 other polymer–solvent systems at high pressure. A comparison with experimental data showed that SRK–LCVM agreed very well with the atmospheric SLE data and that PC‐SAFT EOS was more efficient in high‐pressure conditions. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Nonisothermal crystallization,melting behavior,and morphology of polypropylene/metallocene‐catalyzed polyethylene blends

The nonisothermal crystallization, melting behavior, and morphology of blends of polypropylene (PP) and a metallocene‐catalyzed polyethylene (mPE) elastomer were studied with differential scanning calorimetry, scanning electron microscopy, polarized optical microscopy, and X‐ray diffraction. The results showed that PP and mPE were partially miscible and could form some cocrystallization, although the extent was very small. A modified Avrami analysis and the Mo method were used to analyze the nonisothermal crystallization kinetics of the blends. The values of the Avrami exponent indicated that the crystallization nucleation of the blends was homogeneous, the growth of the spherulites was three‐dimensional, and the crystallization mechanism of PP was not affected by mPE. The crystallization activation energy was estimated with the Kissinger method. Interesting results were obtained with the modified Avrami analysis and Mo and Kissinger methods, and the conclusions were in good agreement. The addition of less mPE increased the overall crystallization rate of PP. The relationship between the composition and morphology of the blends was examined. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 1203–1210, 2004     

Effect of dynamic shear on the microcellular foaming of polypropylene/high‐density polyethylene blends

Dynamic shear in the axial direction of a rotor was vertically superposed on the melt flow direction, and its effects on the shear rate and melt strength were investigated theoretically. Polypropylene/high‐density polyethylene blends were microcellularly foamed with different vibration parameters. The experimental results were compared with those of a theoretical analysis, and the effects of dynamic shear on the foamability and ultimate cell structure were analyzed in detail. The theoretical results showed that the shear rate and melt strength increased with an increase in the vibration amplitude and frequency. The enhanced melt strength could effectively restrict cell growth, prevent cell rupture, and improve foamability. The experimental results showed that the cell orientation decreased and the cell structure was improved when axial dynamic shear induced by rotor vibrations was superposed on the melt flow direction. Furthermore, the cell diameter decreased and the cell density increased with increases in the vibration amplitude and frequency. The experimental results were very consistent with the theoretical analysis. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Ultraviolet weathering of photostabilized wood‐flour‐filled high‐density polyethylene composites

Wood‐plastic composites are being increasingly examined for nonstructural or semistructural building applications. As outdoor applications become more widespread, durability becomes an issue. Ultraviolet exposure can lead to photodegradation, which results in a change in appearance and/or mechanical properties. Photodegradation can be slowed through the addition of photostabilizers. In this study, we examined the performance of wood flour/high‐density polyethylene composites after accelerated weathering. Two 2⁴ factorial experimental designs were used to determine the effects of two hindered amine light stabilizers, an ultraviolet absorber, a colorant, and their interactions on the photostabilization of high‐density polyethyl‐ ene blends and wood flour/high‐density polyethylene composites. Color change and flexural properties were determined after 250, 500, 1000, and 2000 h of accelerated weathering. The results indicate that both the colorant and ultraviolet absorber were more effective photostabilizers for wood flour/high‐density polyethylene composites than the hindered amine light stabilizers. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 2609–2617, 2003     

Mechanical and thermal properties of high‐density polyethylene toughened with glass beads

Glass beads were used to improve the mechanical and thermal properties of high‐density polyethylene (HDPE). HDPE/glass‐bead blends were prepared in a Brabender‐like apparatus, and this was followed by press molding. Static tensile measurements showed that the modulus of the HDPE/glass‐bead blends increased considerably with increasing glass‐bead content, whereas the yield stress remained roughly unchanged at first and then decreased slowly with increasing glass‐bead content. Izod impact tests at room temperature revealed that the impact strength changed very slowly with increasing glass‐bead content up to a critical value; thereafter, it increased sharply with increasing glass‐bead content. That is, the Izod impact strength of the blends underwent a sharp transition with increasing glass‐bead content. It was calculated that the critical interparticle distance for the HDPE/glass‐bead blends at room temperature (25°C) was 2.5 μm. Scanning electron microscopy observations indicated that the high impact strength of the HDPE/glass‐bead blends resulted from the deformation of the HDPE matrix. Dynamic mechanical analyses and thermogravimetric measurements implied that the heat resistance and heat stability of the blends tended to increase considerably with increasing glass‐bead content. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 89: 2102–2107, 2003     

Morphology and mechanical properties of polypropylene and poly(ethylene‐co‐methyl acrylate) blends

The morphology and mechanical properties of isotactic polypropylene (iPP) and poly(ethylene‐co‐methyl acrylate) (EMA) blends were investigated. Various EMA copolymers with different methyl acrylate (MA) comonomer content were used. iPP and EMA formed immiscible blends over the composition range studied. The crystallization and melting reflected that of the individual components and the crystallinity was not greatly affected. The size of the iPP crystals was larger in the blends than those of pure iPP, indicating that EMA may have reduced the nucleation density of the iPP; however, the growth rate of the iPP crystals was found to remain constant. The tensile elongation at break was greatly increased by the presence of EMA, although the modulus remained approximately constant until the EMA composition was greater than 20%. EMA with a 9.0% MA content provided the optimum effect on the mechanical properties of the blends. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 90: 175–185, 2003     

Mechanical properties of Mg(OH)2/polypropylene composites modified by functionalized polypropylene

Modified Mg(OH)₂/polypropylene (PP) composites were prepared by the addition of functionalized polypropylene (FPP); and acrylic acid (AA) and by the formation of in situ FPP. The effects of the addition of FPP and AA and the formation of in situ FPP on the mechanical properties of Mg(OH)₂/PP composites were investigated. Experimental results indicated that the addition of Mg(OH)₂ markedly reduced the mechanical properties of PP. The extent of reduction in notch impact strength of PP was higher than that in flexural strength and tensile strength. However, tensile modulus and flexural modulus increased with increased Mg(OH)₂ content. The addition of FPP facilitated the improvement in the flexural strength and tensile strength of Mg(OH)₂/PP composites. The higher the Mg(OH)₂ content was, the more significant the effect of FPP was. The incorporation of AA resulted in further increased mechanical properties, in particular the flexural strength, tensile strength, and notch impact strength of Mg(OH)₂/PP composites containing high levels of Mg(OH)₂. It not only improved mechanical properties but also increased the flame retardance of Mg(OH)₂/PP composites. Although the mechanical properties of composites modified by the formation of in situ FPP were lower than those of composites modified by only the addition of AA in the absence of diamylperoxide, the mechanical properties did not decline with increased Mg(OH)₂ content. Moreover, the mechanical properties increased with increasing AA content. The addition of an oxidation resistant did not influence the mechanical properties of the modified Mg(OH)₂/PP composites. © 2003 Wiley Periodicals, Inc. J Appl Polym Sci 88: 2139–2147, 2003     

Conductivity of polyolefins filled with high‐structure carbon black

The electrical conductivities of various polyolefins filled with a high‐structure carbon black (CB) were studied. Typical percolation behaviors were observed in all of the materials studied. At a critical CB content, which defined the percolation threshold, CB formed conductivity pathways, and resistivity fell sharply from a value characteristic of an insulator into the range of 10–100 Ω cm. The dependence of the percolation threshold on the matrix viscosity was understood in terms of competing effects on CB dispersion during blending and CB flocculation during compression molding. For the conditions used in this study, polypropylene with a melt flow index of about 50 was optimum. Flocculation in the quiescent melt was studied directly by atomic force microscopy. Conductivity pathways formed over time by CB agglomeration. The temperature dependence of the percolation time was described by an Arrhenius relationship. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 98: 1799–1805, 2005     

Compatibilization of polypropylene/nylon 6 blends with a polypropylene solid‐phase graft

The compatibilization of polypropylene (PP)/nylon 6 (PA6) blends with a new PP solid‐phase graft copolymer (gPP) was systematically studied. gPP improved the compatibility of PP/PA6 blends efficiently. Because of the reaction between the reactive groups of gPP and the NH₂ end groups of PA6, a PP‐g‐PA6 copolymer was formed as a compatibilizer in the vicinity of the interfaces during the melting extrusion of gPP and PA6. The tensile strength and impact strength of the compatibilized PP/PA6 blends obviously increased in comparison with those of the PP/PA6 mechanical blends, and the amount of gPP and the content of the third monomer during the preparation of gPP affected the mechanical properties of the compatibilized blends. Scanning electron microscopy and transmission electron microscopy indicated that the particle sizes of the dispersed phases of the compatibilized PP/PA6 blends became smaller and that the interfaces became more indistinct in comparison with the mechanical blends. The microcrystal size of PA6 and the crystallinity of the two components of the PP/PA6 blends decreased after compatibilization with gPP. The compatibilized PP/PA6 blends possessed higher pseudoplasticity, melt viscosity, and flow activation energy. © 2004 Wiley Periodicals, Inc. J Appl Polym Sci 93: 420–427, 2004     

Bi‐axial self‐reinforcement of high‐density polyethylene induced by high‐molecular weight polyethylene through dynamic packing injection molding

Previously, bi‐axial self‐reinforcement of high‐density polyethylene (HDPE) was achieved through a uni‐axial shear stress field introduced by dynamic packing injection molding technology. Here, further improvement of tensile strength along the flow direction (MD) was achieved by blending a small amount of high‐molecular‐weight polyethylene (HMWPE) with HDPE, while the tensile strength along the transverse direction (TD) still substantially exceeded that of conventional moldings. Tensile strengths in both flow and transverse directions were considerably enhanced, with improvements from 23 MPa to 76 MPa in MD and from 23 MPa to 31 MPa in TD. The effect of HMWPE content and molding parameters on tensile properties was also investigated. The tensile strength along MD was highly dependent on HMWPE content, oscillating cycle, mold temperature, melt temperature and packing pressure, while that along TD was insensitive to composition and processing parameters within the selected design space. According to the stress–strain curves, samples with HMWPE produced by dynamic packing injection molding had a special tensile failure mode in MD, different from both typical plastic and brittle failure modes. There were no yielding and necking phenomena, which are characteristic during tensile testing of plastic materials, but there was still a considerably higher elongation compared to those of brittle materials. However, in TD, all dynamic injection molding samples exhibited plastic failure as did typical conventional injection molding samples. Copyright © 2006 Society of Chemical Industry     

Miscibility and crystallization of metallocene polyethylene blends with polypropylene

The crystallization and morphology of very‐low‐density polyethylene (VLDPE) and ultra‐low‐density polyethylene (ULDPE) blends with isotactic polypropylene (PP) were studied by differential scanning calorimetry (DSC) and hot‐stage optical microscopy (HSOM) with polarized light. In particular, the isothermal crystallization of PP in molten PE was investigated. A polypropylene homopolymer was melt‐blended with six types of VLDPEs and ULDPEs, with variations in branch content and length and in molecular weight. All the blends contained 20% PP by mass. It was found that the crystallization temperatures of PP and PE changed in the blends, and the crystallization of PP was affected by branch length and content and by the molecular weight of the PE, indicating a certain degree of miscibility between PP and PE. The isothermal crystallization rate of PP decreased in the blends; in particular, the crystallization rate of PP was slower in the ULDPE with lower MFI, suggesting that crystallization of PP was hindered by PE and that its rate was regulated by the viscosity of ULDPE. HSOM images showed that a portion of the PP crystallized from molten PE, although phase separation was obvious, providing additional information on the miscible behavior between PP and VLDPEs (or ULDPEs). Furthermore, the miscible level between the PP and the ULDPEs was higher than that between the PP and the VLDPEs because the degree of change in the crystallization behavior of the PP and PE was greater in the PP–ULDPE blends. This was possibly a result of the higher branch content in the ULDPE. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 87: 1179–1189, 2003     

Rheological properties of polypropylene modified by high‐intensity ultrasonic waves

A new method using high‐intensity ultrasonic waves, instead of peroxide‐aided reactive extrusion, was applied to modify a linear polypropylene into a branched structure. The ultrasonic waves induced chain scission and created reactive macromolecules of polypropylene successfully in the melt state without any peroxide. To enhance and control the recombination reaction during sonication, a multifunctional agent and an antioxidant were used. The rheological property measurements clearly confirmed that the modified polypropylene had a nonlinear branched structure. It showed shear‐thinning behaviors in its viscosities at low frequencies, high elastic behaviors in Cole–Cole plots, and a high rheological polydispersity index in comparison with a linear polypropylene. The degradation or recombination of polypropylene was adequately controlled by an antioxidant, which stabilized the structure during sonication. Also, the use of an antioxidant was quite effective in improving the extrusion processability by delaying the instability of the extrudate to a higher shear rate. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci, 2006     

New fluorine‐containing bissalicylidenimine–titanium complexes for olefin polymerization

Three new titanium complexes bearing salicylidenimine ligands—bis[(salicylidene)‐2,3,5,6‐tetrafluoroanilinato]titanium(IV) dichloride ( 1 ), bis[(3,5‐di‐tert‐butylsalicylidene)‐2,3,5,6‐tetrafluoroanilinato]titanium(IV) dichloride ( 2 ), and bis[(3,5‐di‐tert‐butylsalicylidene)‐4‐trifluoromethyl‐2,3,5,6‐tetrafluoroanilinato]titanium(IV) dichloride ( 3 )—were synthesized. The catalytic activities of 1 – 3 for ethylene polymerization were studied with poly(methylaluminoxane) (MAO) as a cocatalyst. Complex 1 was inactive in ethylene polymerization. Complex 2 at a molar ratio of cocatalyst to pre catalyst of Al_MAO/Ti = 400–1600 showed very high activity in ethylene polymerization comparable to that of the most efficient metallocene complexes and titanium compounds with phenoxy imine and indolide imine chelating ligands. It gave linear high‐molecular‐weight polyethylene [weight‐average molecular weight (M_w) ≥ 1,700,000. weight‐average molecular weight/number‐average molecular weight (M_w/M_n) = 4–5] with a melting point of 142°C. The ability of the 2 /MAO system to copolymerize ethylene with hexene‐1 in toluene was analyzed. No measurable incorporation of the comonomer was observed at 1:1 and 2:1 hexene‐1/ethylene molar ratios. However, the addition of hexene‐1 had a considerable stabilizing effect on the ethylene consumption rate and lowered the melting point of the resultant polymer to 132°C. The 2 /MAO system exhibited low activity for propylene polymerization in a medium of the liquid monomer. The polymer that formed was high‐molecular‐weight atactic polypropylene (M_w ～ 870,000, M_w/M_n = 9–10) showing elastomeric behavior. The activity of 3 /MAO in ethylene polymerization was approximately 70 times lower than that of the 2 /MAO system. © 2005 Wiley Periodicals, Inc. J Appl Polym Sci 95: 1040–1049, 2005     

PP/LDPE blends produced by reactive processing. I. Grafting efficiency and rheological and high‐elastic properties of [PP/LDPE]‐g‐IA melts

Itaconic acid (IA) was grafted onto polypropylene/low‐density polyethylene (PP/LDPE) blends. The ratio of polymeric components was varied from 100 : 0 to 0 : 100. The effect of the variation in the ratios of the components on grafting efficiency and concomitant side processes was studied. Grafting of IA (1 wt %) was initiated by 2,5‐dimethyl‐2,5‐di(tert‐butyl peroxy)‐hexane (0.3 wt %) and was carried out in an extruder reactor equipped with a dynamic mixer. An increase in the PP content of the blend led to a lower yield of the grafted product. With low concentrations of LDPE in the blend (up to 25 wt %), grafting efficiency was observed to increase, and this increase was greater in comparison with the additive rule. Between 25 and 99 wt % of LDPE in the blend, grafting efficiency rose monotonically with LDPE concentration. At or below an LDPE content of 25 wt %, the melt flow index (MFI) of [PP/LDPE]‐g‐IA would increase unlike with PP‐g‐IA systems. But a small quantity of PP (below 25 wt %) in the [PP/LDPE]‐g‐IA blends would result in a decreased MFI unlike with LDPE‐g‐IA. The dependence of swell index and melt strength on the ratio of polymeric components in [PP/LDPE]‐g‐IA blends also was investigated. ©2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 5095–5104, 2006     

Effect of corn‐zein coating on the mechanical properties of polypropylene packaging films

In this study, a novel film structure of corn zein coated on polypropylene (PP) synthetic films for food packaging applications was developed, and the mechanical properties of the resulting coated film, as affected by the coating formulation, were investigated. Composite structures of PP films coated with corn zein were obtained through a simple solvent casting method. Different amounts of corn zein (5 and 15%) were dissolved in 70 and 95% aqueous ethanol solution at 50°C. Solutions of corn zein plasticized with poly(ethylene glycol) and glycerol (GLY) at various levels (20 and 50%) were applied on corona‐discharge‐treated PP. A statistical analysis based on full factorial design was performed to examine the influence of the coating formulation on the final properties of the corn‐zein‐coated PP films. A significant (p < 0.05) improvement in the coated film's mechanical properties was observed compared to those of the uncoated PP. The effect of the plasticization of the coating solutions was also quite significant. In general, GLY provided better improvements in the mechanical properties of the corn‐zein‐coated PP films. The statistical analysis of the results showed that the corn‐zein and plasticizer concentrations and plasticizer type used in the coating formulations were more effective parameters and had significant effects on the mechanical behavior of the coated PP films. In conclusion, corn‐zein coatings could have potential as alternatives to conventional synthetic polymers used in composite multilayer structures for food packaging applications. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Flammability and mechanical properties of wood flour‐filled polypropylene composites

Polypropylene (PP) composites filled with wood flour (WF) were prepared with a twin‐screw extruder and an injection‐molding machine. Three types of ecologically friendly flame retardants (FRs) based on ammonium polyphosphate were used to improve the FR properties of the composites. The flame retardancy of the PP/WF composites was characterized with thermogravimetric analysis (TGA), vertical burn testing (UL94‐V), and limiting oxygen index (LOI) measurements. The TGA data showed that all three types of FRs could enhance the thermal stability of the PP/WF/FR systems at high temperatures and effectively increase the char residue formation. The FRs could effectively reduce the flammability of the PP/WF/FR composites by achieving V‐0 UL94‐V classification. The increased LOI also showed that the flammability of the PP/WF/FR composites was reduced with the addition of FRs. The mechanical property study revealed that, with the incorporation of FRs, the tensile strength and flexural strength were decreased, but the tensile and flexural moduli were increased in all cases. The presence of maleic anhydride grafted polypropylene (MAPP) resulted in an improvement of the filler–matrix bonding between the WF/intumescent FR and PP, and this consequently enhanced the overall mechanical properties of the composites. Morphological studies carried out with scanning electron microscopy revealed clear evidence that the adhesion at the interfacial region was enhanced with the addition of MAPP to the PP/WF/FR composites. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010