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

Morphology Distribution in Injection Molded Parts

A more sustainable use of plastic parts makes it necessary to replace current plastic parts with recyclable components, also allowing the modulation of the part properties through the process. Injection molding is one of the most widely used technologies for obtaining rigid plastic parts, so it is crucial to understand how to tailor properties by adopting the correct processing conditions. One way is to perform annealing steps directly inside the mold: in-mold annealing improves the structural integrity and durability of the material, reduces defects, increases the resistance of parts against certain chemicals, reduces wear and tear, increases ductility, and lowers brittleness. In this work, several in-mold annealing steps were conducted, changing the mold temperature and annealing duration selected on the basis of the half crystallization time of the adopted isotactic polypropylene. The typical molded part morphology, composed of oriented layers at the surface, transition zones, and spherulitic core, is strongly affected by in-mold annealing. In particular, the thickness of the oriented layer, which forms in the early phase of the process, decreases, and the spherulites increase in size. Concerning mechanical behavior, the orientation degree mostly determines the elastic modulus value close to the surface, whereas the conditions under which crystallization occurs determine the modulus in the core.

Enhancing the Sound and Thermal Insulation Properties of Polypropylene Foam by Preparing High Melt Strength Polypropylene

High-performance polypropylene (PP) foam is a vital polymer product in industrial areas. However, the poor melt strength of ordinary PP homopolymer limits its foaming molding. In this work, high melt strength polypropylene (HMSPP) is prepared by using styrene (St) and tripropylene glycol diacrylate (TPGDA) as comonomers, and then PP foams are prepared by mold foaming method. The results show that adding St in the grafting process of TPGDA will obviously improve the melt strength of the PP matrix, and its melt strength (28 184 Pa.s) is 7.4 times higher than that of pure PP. HMSPP foam has more regular and uniform cells and higher cell density, which significantly improves the sound and thermal insulation properties of PP foam. Compared with pure PP foam, the average sound transmission loss (52.9 dB) of HMSPP foam with a low foaming ratio increased by 64%, and the thermal conductivity (0.0867 W mK-1 ) decreased by 46%. Therefore, the obtained HMSPP foam can be used in sound insulation or thermal insulation area. This work provides an available route for the high-performance utilization of PP foam.