Effect of Injection Parameters and Addition of Nanoscale Materials on the Shrinkage of Polypropylene Copolymer

The effect of variation of injection conditions and addition of nano-calcium carbonate (CaCO₃), nano-silicon dioxide (SiO₂) and full-vulcanized nano-powdered styrene butadiene rubber (PSBR) on the shrinkage of injection-molded polypropylene-ethylene copolymer (90/10, co-PP) were investigated. The results showed that the shrinkage was different for different locations along the flow path. The shrinkage in the length direction of the injection-molded sample varied with the adjustment of the processing parameters, while the shrinkage in the width and thickness direction was almost unchanged. The addition of nano-CaCO₃ and PSBR decreased the shrinkage of co-PP, while the shrinkage of co-PP/ SiO₂ composite was almost unchanged.     

Mechanical Properties and Crystallization Behavior of Polycarbonate/Polypropylene Blends

The mechanical properties, morphology, and crystallization behavior of polycarbonate (PC)/polypropylene (PP) blends, with and without compatibilizer, were studied by tensile and impact tests, scanning electron microscopy (SEM), X-ray diffraction (XRD), and differential scanning calorimetry (DSC). The tensile and impact strengths of PC/PP blends decreased with increasing the PP content due to poor compatibility between the two phases. But the addition of compatibilizer improved the mechanical properties of the PC/PP blends, and the maximum value of the mechanical properties, such as tensile and impact strengths of PC/PP (80/20 wt%) blends, were obtained when the compatibilizer was used at the amount of 4 phr. The SEM indicated that the compatibility and interfacial adhesion between PC and PP phases were enhanced. DSC results that showed the crystallization and melting peak temperatures of PP increased with the increase of the PP content, which indicated that the amorphous PC affected the crystallization behavior. However, both the PC and compatibilizer had little effect on the crystallinity of PP in PC/PP blends based on both the DSC and XRD patterns.     

Mechanical Properties and Rheological Behavior of Dynamically Vulcanized Trans-Polyisoprene/Polypropylene Blends

The degree of dynamic vulcanization, mechanical properties, rheological behavior, and the ageing-resistant performance of thermoplastic vulcanizates (TPVs) based on Trans 1,4-polyisoprene/polypropylene (TPI/PP) blends with the blend ratios of 70/30, 60/40, and 50/50 were investigated. The results showed that TPI fully dynamically vulcanized in the Haake mixer chamber when mixed with PP, and the specimen with the blend ratio 70/30, for the same sulfur content in all samples, had the lowest cross-linking degree of the TPI phase. The shear viscosity of TPI/PP-TPVs dropped as the shear rate increased and the specimen with the blend ratio 70/30 had a relatively greater shear viscosity in the region of shear rates less than 1000 s^?1. With the antiageing agent Vulkanox 4020 NA (Bayer) added, all the TPI/PP-TPVs showed good ageing characteristics, and the specimen with the blend ratio 70/30 possessed the best mechanical properties.     

Mechanical,Thermal, and Surface Properties of Ultrahigh Molecular Weight Polyethylene/Polypropylene Blends

Various compositions of ultrahigh molecular weight polyethylene/polypropylene (UHMWPE/PP) blends were prepared in decalin, with the rheological, mechanical, thermal, and surface properties of the blends being determined using the solution cast film. Viscosity and mechanical properties of the blends decreased below the additivity value with increasing PP content implying that PP molecules disturb the entanglement of UHMWPE. Contact angle of the blend films with a water drop increased with increasing content of PP. The atomic force microscope (AFM) images showed that the surface of cast UHMWPE was very smooth whereas that of cast PP was very uneven. For blends, the surface became rough and uneven with increasing content of PP. The melting temperature of PP (T _mP) decreased in the blends with increasing UHMWPE content while that of UHMWPE (T _mU) remained almost constant in blends.     

Electrical Properties of Isotactic Polypropylene/Multiwalled Carbon Nanotubes Composites Prepared by Vibration Injection Molding

To study the effect of vibration field on the electrical conductivity properties of nanocomposites, isotactic polypropylene (iPP)/multiwalled carbon nanotubes (MWCNT) composites were prepared by conventional injection molding and vibration injection molding. Results showed that the electrical conductivity of iPP/MWCNT composites was significantly promoted by vibration injection molding. Vibration injection molded samples had a percolation threshold of about 2.7 wt% compared with the threshold of about 4.5 wt% for conventional injection molded samples. The effects of test locations and vibration frequency on the electrical conductivity of composites were investigated. The samples exhibited an inhomogeneity along the injection direction. The electrical conductivity of the samples was different at different test locations and increased with increasing vibration frequency. Polarized light microscopy (PLM) results indicated that vibration injection molding can induce MWCNT aggregates to be stretched and oriented along the flow direction, which could form conductive networks and greatly enhance the electrical conductivity of iPP/MWCNT composites.     

Evaluation of Effect of Plastic Injection Molding Process Parameters on Shrinkage Based on Neural Network Simulation

The effects of process parameters, mold temperature (T _mo), melt temperature (T _me), cooling time (t_c ), fill pressure (P_f ), packing pressure (P_p ), and packing time (t_p ) on the shrinkage of injection molded polypropylene were investigated by utilizing a combination of the Artificial Neural Network (ANN) method and Moldflow software. An ANN model is developed to understand the relationship between plastic injection molding process parameters and shrinkage. The test results on the performance of the ANN model show that it can predict the shrinkage with reasonable accuracy. The simulation results show that the most important process parameter affecting shrinkage is P_p , followed by T _me and T _mo, with t_c , P_f , and t_p having the least effect. Shrinkage increases with the elevated T _mo and t_c . In contrast, the increases in P_p , T_me , t_p , and P_f cause shrinkage to decrease. The strongest effect on the shrinkage is the amount of material forced into the mold, followed by the crystallinity and orientation of the material.     

Mechanical Properties of Rubber Sheets Produced by Direct Molding of Ground Rubber Tire Powder

The so called “direct powder molding” is a compressions molding process which can be directly applied to ground rubber tire (GRT). This study shows that the GRT can be re-used to produce medium-size parts with good mechanical properties without any addition of virgin rubber. For rubber sheets prepared from the mechanically ground rubber tire (MGRT) and the cryogenically ground rubber tire (CGRT), the densities and crosslink densities of the rubber sheets increased with a decrease of the particle size of the waste tire powder. The tensile strength of the rubber sheets increased with the decreasing of the particle size for the two types of waste tire powder to 250 μm and 120 μm, respectively, and then became level. The moulding pressure had no effect on the densities, tensile strength or elongation at break of the rubber sheets. These results suggested that the effect of the particle size is important and is correlated with the mechanical properties of the rubber sheets produced by direct powder moulding technology. In general, the best mechanical properties were obtained with waste tire rubber with a size of about 250 μm for the rubber particles obtained from the mechanical grinding method of waste tire powdering.     

Morphologies and Mechanical Properties of High-Density Polyethylene Induced by the Addition of Small Amounts of Both Low- and High-Molecular-Weight Polyolefin under Shear Stress Applied by Dynamic Packing Injection Molding

This paper focuses on the mechanical properties and crystal morphology of a self-reinforced high-density polyethylene 5000S (HDPE 5000S) by simultaneously blending with 9 wt% high-molecular-weight polyethylene (HMWPE) and 9 wt% low-molecular-weight polyethylene (LMWPE) (A9) under the shear stress field which was engendered by a self-made dynamic packing injection molding (DPIM) machine. The results of mechanical properties, differential scanning calorimetry, and scanning electron microscopy characterization were as follows: (1) The tensile strength of the dynamic samples increased to 112.1 MPa, 4.85 times as much as that of static packing injection molding (SPIM) samples (23.1 MPa), as a result of realizing polyethylene's self-enhancement; (2) Shish-kebab structure was found in the dynamic samples; (3) The crystallinity of the DPIM A9 sample reached 68.6%, on increase by 18.7% compared with that of the SPIM sample. The formation of the shish-kebab structure and enhancement of mechanical properties are explained.     

Piezoelectric Performance of Microcellular Polypropylene Foams Fabricated Using Foam Injection Molding as a Potential Scaffold for Bone Tissue Engineering

Abstract

Piezoelectric properties and adequate porosity play important roles in bone tissue engineering. In this paper we describe the fabrication of piezoelectric polypropylene (PP) foam using injection molding to be utilized as a potential cost-effective scaffold for bone tissue engineering. One-side mechanical skin removal from the foam was used to investigate the effect of the solid skin on the piezoelectric performance. The microcellular structure, relative density, crystalline structure, mechanical properties, piezoelectric properties under repeated impact pressure and biocompatibility of the scaffolds were investigated using scanning electron microscopy (SEM), water displacement method, differential scanning calorimetry (DSC), uniaxial tension tests, piezoelectric tests and MTT assays, respectively. Uniform spherical cells, with an average size of 75?µm and a density of 1.23?×?10⁶ cells/cm^?3, suitable for bone regeneration, were imaged by SEM. The DSC results showed β crystals formation in the PP foam during the foaming process which would be valuable for mechanical properties. The foaming process did not reduce the mechanical properties significantly. The foaming process promoted the piezoelectric responses by 134, 922, and 87%, respectively, for the PP samples with 3, 2 and 1?mm thickness. The biocompatibility test suggested improved cellular biocompatibility by foaming. Overall, the results demonstrated the development of a cost-effective scaffold for tissue engineering.     

Nanofilled Polypropylene/Poly(trimethylene terephthalate) Blends: A Morphological and Mechanical Properties Study

Polypropylene (PP) /poly(trimethylene terephthalate), (PTT), binary blends in the presence of two interfacial modifier as well as two organically modified nanoclay additives were studied in terms of mechanical and morphological characteristics. Scanning electron microscopy confirmed the incompatibility of the system which was solved to some extent through incorporating the nanoclay as well as functional compatibilizers. An evaluation of the specimens via static mechanical tests in tensile mode gave credence to the assumption that the higher the PTT content, the higher the mechanical performance would be. Furthermore, the compatibilizer-containing blends not only exhibited higher toughness, but also possessed enhanced stiffness when a maleated compatibilizer was added. The tensile modulus was promoted further in the presence of clay nanoparticles; however, toughness was somewhat sacrificed. The Barentsen as well as Halpin-Tsai models were found to describe the binary blends modulus. The reinforcing impact of the nanoclay was exploited to a greater degree in the presence of the compatibilizer.     

Properties of Polypropylene/Antibacterial Glass Composites

Polypropylene (PP)/antibacterial glass composites were prepared by melt blending PP and silver-doped glass. The antibacterial activity of the PP composites was examined by the method of plate counting, and the crystallization behaviors of pure PP and antibacterial glass/PP composites were compared via hot-stage polarized optical microscopy (POM), X-ray diffraction (XRD), and differential scanning calorimeter (DSC). The results revealed that the antibacterial PP composites had effective antibacterial activity with antibacterial rates more than 90%. The antibacterial agent in the antibacterial glass/PP composites acted as nucleating agents, increasing the crystallization temperature and crystallization rate of PP, but not changing the crystalline modification of PP. The mechanical properties of antibacterial glass/PP composites were also studied, and the results showed that the antibacterial glass improved the stiffness and modulus but decreased the notched impact strength of the PP composites.     

Comparison of Mechanical Properties and Rheological Behavior of Trans-Polyisoprene/Polypropylene and Ethylene Propylene Diene Rubber/Polypropylene Thermoplastic Vulcanizates

The degree of dynamic vulcanization, mechanical properties, rheological behavior, and the ageing-resistant performance of trans 1,4-polyisoprene (TPI)/polypropylene (PP) and ethylene propylene diene rubber (EPDM)/PP thermoplastic vulcanizates with a blend ratio of 60/40 were investigated comparatively. The results showed that TPI had fully dynamically vulcanized when mixed with PP in the Hakke mixer chamber (175°C, 60 rpm) while EPDM had only partly dynamically vulcanized due to its saturated main chain backbone. With increased sulfur content, the torque at the end of the curing curves of the two thermoplastic vulcanizates (TPVs) increased in the curing characteristics measuring process as the degree of crosslinking increased. Comparing the two blends, TPI/PP-TPVs were possessed of a better mobility, a little lower tensile strength and tear strength, a little higher 100% modulus and hardness, and much lower elongation at break. EPDM/PP-TPVs had better ageing-resistant characteristics due to EPDM's saturated main chain backbone.     

Effect of an In-Situ Nucleating Agent on the Polymorphs and Mechanical Properties of Isotactic Polypropylene

The influence of glutaric acid (GA)/cadmium hydroxide [Cd(OH)₂] mixtures on the crystallization and properties of isotactic polypropylene (iPP) was investigated by means of differential scanning calorimetry (DSC), wide angle X-ray diffraction (WAXD), polarized light microscopy, and mechanical tests. It was found that the β-crystalline form was produced in the samples containing 0.15 wt% GA and more than 0.17 wt% Cd(OH)₂. The content of β-crystalline form was maximum, i.e. K_DSC = 65.4% and K_WAXD = 71.4%, when the sample was doped with GA (0.15 wt%)/Cd(OH)₂ (0.20 wt%) (the molar ratio of GA:Cd(OH)₂ was 1:1.2). It was also found that GA/Cd(OH)₂ mixtures not only induced the β-crystalline form but also made spherulites smaller. The results of mechanical tests showed that the toughness of iPP was greatly improved by bicomponent nucleator, while the stiffness decreased a little. Fourier transform infrared spectroscopy analysis indicated that an “in-situ” chemical reaction occurred between GA and Cd(OH)₂ during melt blending, yielding an effective β nucleator (cadmium glutarate).     

Study of Energy Consumption in the Injection Molding Process

A computing method for simulating the energy consumption in an injection molding process using the Moldflow MPI analysis software is proposed. Considering such factors as product structure, processing parameters, and mold structure, it was shown by orthogonal testing that the melt temperature, product diameter, product wall thickness, and gate diameter are the four largest factors impacting on the injection energy consumption. Based on the MATLAB curve fitting toolbox, the relationship between the four main factors and the injection energy consumption was established, and a calculation model for the injection energy consumption was proposed.The accuracy of the model was above 95%. Finally, by using an experimental system of injection energy consumption to research the relationship between energy consumption and actual injection power, and by verifying the calculation accuracy of injection energy consumption of the established model, the results show that the established model can be an excellent predictor of the actual electric energy required and the accuracy of it was above 85% compared with measured experimental data.     

Mechanical Properties and Morphology of LDPE/PP Blends

Two types of polypropylene (PP) with different molecular structure, namely, homogeneous PP (PPH) and PP block‐copolymer (PPC), were blended with a long chain, branched, low density polyethylene (LDPE) in a twin screw extruder and then injection moulded into test specimens; the mechanical properties and morphology of the blends are reported. The tensile strength, elastic modulus, flexural strength, and flexural modulus of the blends increased monotonically with increasing PP content, although exhibiting a slightly negative deviation from the rules of mixtures due to the relatively poor compatibility of the components, which caused the blends to separate into individual phases. Comparatively, these mechanical properties of the LDPE/PPH blend were much higher than that of the LDPE/PPC blend, which was attributable mainly to the fact that the mechanical properties of neat PPH are stronger than that of neat PPC. With respect to the impact strength of the blends, a maximum value appeared in LDPE/PPH blends when PPH content was about 20% and also in LDPE/PPC blends when PPC content was about 40%.     

Preparation and Properties of Polypropylene/Organo-Vermiculite Nanocomposites

Polypropylene/organo-vermiculite (OVMT) nanocomposites with different clay loadings were prepared via melt-mixing using a twin-screw extruder. The vermiculite was premodified with maleic anhydride by ball milling. The resultant polypropylene/OVMT nanocomposites possess an intercalated structure as confirmed by both wide-angle X-ray diffraction (WAXD) and transmission electron microscopy (TEM). The mechanical property tests show that the tensile and flexural strength of these nanocomposites increase dramatically with the OVMT loading; the fracture toughness remains almost unchanged and the Charpy impact strength decreases slightly. Finally, differential scanning calorimetry (DSC) and WAXD results show that the addition of vermiculite can induce the β crystal structure of polypropylene.     

Self-Reinforced High-Density Polyethylene Prepared by Low-Frequency,Vibration-Assisted Injection Molding. 1. Processing Conditions and Physical Properties

Using a low-frequency, vibration-assisted injection molding (VAIM) device, the effects of vibration variables (frequency and amplitude) on mechanical properties and thermal softening temperature of high-density polyethylene (HDPE) injection moldings were investigated. For VAIM-processed samples, the mechanical properties can be improved by changing vibration frequency and vibration pressure amplitude. Injected at a constant vibration pressure amplitude, a low range of frequency (below 0.7 Hz) was favorable for increasing yield strength; in the high range of frequency (0.7 Hz < f < 2.33 Hz) the yield strength remained at a plateau. Injected at a constant frequency (0.7 Hz) the yield strength increased sharply with decreased elongation when applying large vibration pressure amplitude. The maximal yield strength and Young's modulus were 60.6 MPa and 2.1 GPa for a VAIM sample compared with 39.8 MPa and 1.0 GPa for a conventional injection-molded (CIM) sample, respectively; there was also a 10°C increase in Vicat softening point temperature.     

Rheological Behaviors of Polypropylene/Poly(1-butene) Blends

The rheological behaviors of polypropylene (PP)/poly(1-butene) (PB) blends with homo-polypropylene (PP₁) or impact polypropylene (PP₂), a poly(propylene-co-ethylene) as the PP component were studied. With increasing of PB resin content for both PP/PB blends, the blends showed higher G'(ω), G''(ω) and η*(ω) at low frequencies but lower values at high frequencies which implied that the processability was improved. A two-phase morphology was observed through the various rheological responses, including G'(ω)-ω terminal region curves, Cole-Cole plots and the weighted relaxation spectra with the PB contents up to 40?wt%. With the same PB content, the rheological parameters of the PP₂/PB blends were quite different from those of the PP₁/PB, which can be attributed to the stronger interaction between PB chains and the ethylene-co-propylene copolymer in PP₂. The impact strength of the PP₂/PB blends was improved dramatically over that of the PP₁/PB. The more significant toughening effect for the PP₂/PB blends can be attributed to the special responses of its rheological behaviors.     

Microstructure and Mechanical Properties of Isotactic Polypropylene Films Fabricated via Melt-Extrusion and Uniaxial-Stretching

In this work, isotactic polypropylene (iPP) melt was slowly extruded through a slit die of a single-screw extruder. Once the iPP melt left the die, it was uniaxially stretched at different stretching rates (SRs). Via this process its microstructure can be manipulated, it was subsequently investigated by wide-angle X-ray diffraction (WAXD), small-angle X-ray scattering (SAXS), differential scanning calorimetry (DSC), polarized optical microscopy (POM), and Fourier transform infrared spectroscopy (FTIR). Furthermore, the mechanical properties (including tensile strength, modulus, toughness, and strain-hardening) were investigated. The results showed that the tensile strength and modulus of the melt-stretched iPP films gradually increased with increasing SRs. In addition, the toughness and elongation at break showed maximum values for iPP films melt-stretched at 30 cm/min. Moreover, compared with other melt-stretched films, the iPP films melt-stretched at 90 cm/min exhibited an obvious strain-hardening behavior at lower strain.     

Structure and Properties of Glass Fiber Reinforced Polypropylene/Liquid Crystal Polymer Blends

A liquid crystal polymer (LCP) was used to improve the physical properties of glass fiber reinforced polypropylene (GFRPP). The LCP was beneficial to improve the mechanical and heat resistant properties of the GFRPP/LCP composite. Compared with the GFRPP with 30% (w%) glass fiber (GF), the yield strength and the impact strength for the GFRPP/LCP composites increased by 62.7% and 18.1%, respectively, with a 6.8°C increase in the Vicat softening temperature for a 5% LCP addition to the GFRPP composites. The crystallinity of the polypropylene (PP) matrix for the GFRPP/LCP composites increased for 5% LCP and then decreased with increasing the LCP content. The γ-phase crystals for the PP matrix occurred in the shear layer of the injection molded GFRPP/LCP samples. The improved adhesion interface between the GF and the PP matrix was beneficial to reinforce and toughen the GFRPP/LCP composites with a small addition of the LCP.