Analysis of thermomechanical reprocessing effects on polypropylene/ethylene octene copolymer blends

Development of a self-reinforced starch-derived film with biocompatibility and mechanical properties

The scraps produced while processing packaging materials will cause a waste of resources. In this study, starch-based self-reinforced film (SSRF) using thermoplastic starch (TPS, 45 wt%) and polypropylene (PP, 53 wt%) was developed. The effect of extrusion times (1-4 times) on the film structure and performance was explored. The results show as the number of extrusions increases, the color of SSRF deepens from gray-white to brown, and the crystallinity increases. The mechanical properties of the four types of SSRF first increase and then decrease. The 2-SSRF has the best performance, with tensile strength of 13.23 MPa, elongation at break of 61.35%, Young's modulus of 1128.99 MPa, and flexural strength of 33.19 MPa. Proper extrusion improves the compatibility of TPS and PP. However, repeated extrusion will cause PP degradation and TPS carbonization, reducing interfacial interaction. This study developed new starch-based self-reinforced film and provided theoretical guidance for reusing packaging material scraps.

Impact of Multiple Reprocessing on Properties of Polyhydroxybutyrate and Polypropylene

Biobased plastics have the potential to be sustainable, but to explore their circularity further, current end-of-life options need to be broadened. Mechanical recycling is one of the most accepted methods to bring back plastics into the loop. Polyhydroxybutyrates (PHBs) are biobased and biodegradable in nature with promising properties and varied applications in the market. This study focuses on their potential for mechanical recycling by multiple extrusion cycles (E1-E5) and multi-faceted characterization of the virgin (V) and reprocessed materials from E1 to E5. The behavior is compared to polypropylene (PP) as a reference with a similar property profile, which has also been reprocessed five times. The thermal properties of both series showed a stable melting point and thermal decomposition temperature from thermal analyses (differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA)). However, a steady increase in the degree of crystallinity was observed which could counterbalance the decrease in molecular weight due to repeated extrusion measured by gel permeation chromatography and resulted in similar values of tensile strength across the cycles. The strain at break was impacted after the first extrusion, but no significant change was observed thereafter; the same was observed for impact strength. Even in scanning electron microscopy (SEM) images, virgin and E5 samples appeared similar, showing the stability of morphological characteristics. Fourier transform infrared spectroscopy (FTIR) results revealed that no new groups are being formed even on repeated processing. The deviation between the PHB and PP series was more predominant in the melt mass flow rate (MFR) and rheology studies. There was a drastic drop in the MFR values in PHB from virgin to E5, whereas not much difference was observed for PP throughout the cycles. This observation was corroborated by frequency sweeps conducted with the parallel plate method. The viscosity dropped from virgin to E1 and E2, but from E3 to E5 it presented similar values. This was in contrast to PP, where all the samples from virgin to E5 had the same values of viscosity. This paper highlights the possibilities of mechanical recycling of PHB and explains why future work with the addition of virgin material and other additives is an area to be explored.

Spin Trapping Analysis of Radical Intermediates on the Thermo-Oxidative Degradation of Polypropylene

The purpose of this study is to investigate the thermo-oxidative degradation behavior of polypropylene (PP) by comparing three types of pristine PP granules (consisting of homopolymer, random copolymer, and block copolymer) with their corresponding oxidized analogues. These analogues were intensely oxidized under oxygen at 90 °C for 1000 h by using the electron spin resonance (ESR) spin trapping method that can detect short-lived radical intermediates during the degradation. The degrees of oxidation could be evaluated by chemiluminescence (CL) intensity, which was related to the concentration of hydroperoxide groups generated in the PP chain. In the pristine PP samples, a small amount of hydroperoxides were found to be formed unintentionally, and their homolysis produces alkoxy radicals, RO•, which then undergo β-scission to yield chain-end aldehydes or chain-end ketones. These oxidation products continue to take part in homolysis to produce their respective carbonyl and carbon radicals. On the other hand, in the oxidized PP granules, because of their much higher hydroperoxide concentration, the two-stage cage reaction and the bimolecular decomposition of hydroperoxides are energetically favorable. Carbonyl compounds are formed in both reactions, which are then homolyzed to form the carbonyl radical species, •C(O)-. PP homopolymer produced the largest amount of carbonyl radical spin adduct; thus, it was found that the homopolymer is most sensitive to oxygen attack, and the presence of ethylene units in copolymers enhances the oxidation resistance of PP copolymers.

The Impact of Reprocessing with a Quad Screw Extruder on the Degradation of Polypropylene

During mechanical recycling, polypropylene typically is reprocessed using a single- or twin-screw extruder. The degradation of polypropylene during this reprocessing reduces the polymer’s molecular weight and, consequently, limits the performance of the recycled resin. This work investigated the impact of a quad screw extruder (QSE), which has greater free volume, on the reprocessing of an impact copolymer polypropylene. To mimic the recycling process, the polypropylene was subjected to three processing cycles using a QSE and a comparable twin-screw extruder (TSE) operated at three screw speeds. The reprocessed materials were characterized for their rheological, morphological, and mechanical properties. For both extruders, increasing the number of reprocessing cycles and the screw speed resulted in higher melt flow indices, decreases in zero-shear viscosity, and shifting of the crossover points for the storage and loss moduli, which indicate reductions in the molecular weight and narrowing of the molecular weight distribution of the polypropylene. The QSE exhibited greater reductions in molecular weight compared to the TSE, probably due to the higher stresses associated with the three intermeshing points along its screws. Reprocessing caused a significant reductions in the Izod impact strength of the reprocessed polypropylene, which correlated with reductions in the particle size and particle size distribution of the dispersed rubbery phase in the polypropylene during reprocessing.

An Industrial Case for Polypropylene Nanocomposite Foams: Lightweight, Soundproof Exterior Automotive Parts

Lightweighting is a challenge for the automotive industry, and foaming is a key technology used to address this problem. A new practical approach is studied to regulate the cell formation of copolymer polypropylene (co-PP) by utilizing graphene nanoplatelets (xGnP) as a process aid during foam injection molding. The approach was designed to enable process freedom to tune part performance by adjusting the amount of xGnP masterbatch. Two different levels of 1–2 wt % xGnP and 0.25–0.35 wt % supercritical fluid (SCF) were investigated. Prepared samples were compared with samples prepared by the traditional method (twin-screw extrusion followed by foam injection molding). The nanocomposite with 2 wt % xGnP comparatively showed about twofold reduction in cell size magnitude. Although the increment in SCF amount resulted in a 47% and 122% enhancement in flexural modulus and strength, respectively, and a 45% loss in Izod unnotched impact strength, the cell size was prone to increasing with regard to low melt strength as compared to neat foams. In conclusion, a 12% weight reduction fulfilled the desired performance parameters in terms of mechanical and sound insulation by utilizing 2 wt % xGnP as a process aid.

Comparison of Properties with Relevance for the Automotive Sector in Mechanically Recycled and Virgin Polypropylene

Polypropylene (PP) has a high recycling potential. However, the properties of mechanically recycled PP (R-PP) have not been fully compared to those of virgin PP (V-PP). Therefore, in this study, properties of R-PP and V-PP were compared using data from recyclers, virgin plastic suppliers, and the literature. The properties of recyclates could not be directly correlated either with the properties of the virgin polymers from which the recyclates were made or the recycling parameters. It was found that the MFR of R-PP was higher; MFR R-PP had a median value (m) of 11 g/10 min while MFR V-PP had a median value of 6.3 g/10 min (at 230 °C and with 2.16 kg). In terms of mechanical properties, in many cases R-PP exhibited stiffer and more brittle behavior, with a slightly higher Young’s modulus (ER-PP = 1400 and EV-PP = 1200 MPa), a reduced elongation at break (ɛbR-PP = 4 l.-% and ɛbV-PP = 83 l.-%), and notched charpy impact strength (NCISR-PP = 4.8 and NCISV-PP = 7.5 kJ/m2). However, the values for every property had a broad distribution. In addition to existing information from the literature, our research sheds fresh light on the variation of the characteristics of recycled polypropylenes presently on the market.

Degradation Behavior of Polypropylene during Reprocessing and Its Biocomposites: Thermal and Oxidative Degradation Kinetics

Non-isothermal thermogravimetric analysis (TGA) was employed to investigate the degradation of polypropylene (PP) during simulated product manufacturing in a secondary process and wood-plastic composites. Multiple batch mixing cycles were carried out to mimic the actual recycling. Kissinger-Akahira-Sunose (KAS), Ozawa-Flynn-Wall (OFW), Friedman, Kissinger and Augis models were employed to calculate the apparent activation energy (E_a). Experimental investigation using TGA indicated that the thermograms of PP recyclates shifted to lower temperatures, revealing the presence of an accelerated degradation process induced by the formation of radicals during chain scission. Reprocessing for five cycles led to roughly a 35% reduction in ultimate mixing torque, and a more than 400% increase in the melt flow rate of PP. E_a increased with the extent of degradation (α), and the dependency intensified with the reprocessing cycles. In biocomposites, despite the detectable degradation steps of wood and PP in thermal degradation, a partial coincidence of degradation was observed under air. Deconvolution was employed to separate the overlapped cellulose and PP peaks. Under nitrogen, OFW estimations for the deconvoluted PP exposed an upward shift of E_a at the whole range of α due to the high thermal absorbance of the wood chars. Under air, the E_a of deconvoluted PP showed an irregular rise in the initial steps, which could be related to the high volume of evolved volatiles from the wood reducing the oxygen diffusion.

Constitutive Modeling of the Tensile Behavior of Recycled Polypropylene-Based Composites

The effect of reprocessing on the quasi-static uniaxial tensile behavior of two commercial polypropylene (PP)-based composites is experimentally investigated and modeled. In particular, the studied materials consist of an unfilled high-impact PP and a talc-filled high-impact PP. These PP composites are subjected to repeated processing cycles, including a grinding step and an extrusion step to simulate recycling at the laboratory level, the selected reprocessing numbers for this study being 0, 3, 6, 9, and 12. Because the repeated reprocessing leads to thermo-mechanical degradation by chain scission mechanisms, the tensile behavior of the two materials exhibits a continuous decrease of elastic modulus and failure strain with the increasing amount of reprocessing. A physically consistent three-dimensional constitutive model is used to predict the tensile response of non-recycled materials with strain rate dependence. For the recycled materials, the reprocessing effect is accounted by incorporating the reprocessing sensitive coefficient into the constitutive model for Young's modulus, failure strain, softening, and hardening equations. Our predictions of true stress-true strain curves for non-recycled and recycled 108MF97 and 7510-are in good agreement with experimental data and can be useful for industries and companies which are looking for a model able to predict the recycling effect on mechanical behavior of polymer-based materials.

Effect of reprocessing cycles on the degradation of PP/PBAT-thermoplastic starch blends

The solid waste management problems caused by the accumulation of plastics require measures to mitigate the environmental damage, and mechanical recycling of plastics is among the possible solutions. In this context, the present study aimed to evaluate the effects of mechanical recycling on the properties of a polypropylene/poly(butylene adipate co-terephthalate)-thermoplastic starch blend (PP/PBAT-Thermoplastic starch blend) when it was subjected to seven reprocessing cycles by a single-screw extruder. The observations by infrared spectroscopy indicated that the chemical structures of the blend and the polypropylene matrix did not present significant changes with the reprocessing cycles. The X-ray diffraction analyses showed that the PP crystals were most affected when reprocessed in their pure form. The observations by thermogravimetry and differential scanning calorimetry indicated that the thermal stability of the blend was higher than that of polypropylene during the extrusion cycles. The scanning electron microscopy images indicated a weak interfacial interaction between the components of the blend, and the mechanical properties showed that the reprocessing improved the elasticity modulus and yield stress, with a consequential decrease of the impact strength.

Interaction simulation and experimental physico-mechanical analysis of distinct polarity blends of polyethylene and polyvinyl alcohol

This paper aimed to investigate the interaction of distinct polarity polymer blends of polyethylene and polyvinyl alcohol (PVOH). Molecular mechanics and dynamics simulation were employed to determine the stability of polyethylene and PVOH complexes. It was found that the binding energies ΔE for all complexes of polyethylene and PVOH are negative values indicating that the interactions between both components are favorable to achieve a lower energy hierarchy. Such interactions are induced by the high polarity hydroxyl groups of PVOH which caused weak distortion to the dipole moment of inherently non-polar polyethylene. Furthermore, the molecular simulation results were compared with tensile strength, X-ray diffraction and morphology analyses. Tensile strength analysis revealed there was a reduction of magnitude for varying PVOH before achieving a maximum value. Adding small quantities of PVOH in polyethylene as the different polar elements would affect the ordered structure within the blends. Nevertheless, the reduction is insignificant due to the polarity of PVOH which has a slightly distorted polar network of polyethylene. The addition of PVOH (5–15 parts per hundred) into a polyethylene matrix has significantly reduced the crystallinity of the polyethylene matrix by disturbing the highly ordered arrangement structures.

Substitution of Virgin Material by Recycled Material from End-of-Life Vehicle (ELV)

The main objective of this study is the substitution of a part of virgin polypropylene with recycled polyolefin from part of End-of-Life Vehicle (ELV) to be used in automobile applications while respecting existing material specifications. First, the recycled plastic sources were characterized by ThermoGravimetric Analysis (TGA), Fourier Transform Infrared Spectrometry (FTIR), Differential Scanning Calorimetry (DSC) and X-ray Fluorescence. As the sources have almost the same properties, the one, with the easiest supply, was selected. During the second step, the study allows comparison of mechanical performance of several formulations with three specific additives made in two injection process conditions. A higher heat temperature and smaller dosage speed reduced the degradation of fibre glass during processing. Moreover, the additive improving the adhesion between the fibre and the polymeric matrix increased by 3% the flexural modulus. This study has enabled the elaboration of a global method coupling sampling methodology, formulation and process optimisation to substitute a virgin material with recycled plastics from ELV.