Dispersion of a novel phenolic rigid organic filler in isotactic polypropylene matrix by solution-mixing and melt-mixing

Abstract

A novel phenolic rigid organic filler (named KD) with a high melting point was dispersed in an isotactic polypropylene (iPP) matrix by solution-mixing and/or melt-mixing. A series of KD/iPP blends was prepared with or without addition of maleic anhydride-grafted polypropylene (MAPP) as a compatibilizer. Influences of MAPP and mixing methods on the filler dispersion were studied using polaried optical microscope (POM), scanning electron microscope (SEM) and tensile test. The filler particles are always inclined to form large irregular aggregates in the iPP matrix due to their significant differences in polarity and solubility in solvent. However, an iPP/MAPP/KD (PMK) blend containing filler particles with a quasi-spherical shape (~97.8 nm in diameter) and narrow particle size distribution (polydispersity index= 1.076) was successfully prepared by incorporating MAPP to reduce the interfacial tension and surface free energy between the dispersion phase and the continuous phase, and adopting a spray-drying method after solution-mixing to suppress the increase of the size of the dispersed phase during the removal of solvent.

Key words： dispersion; rigid organic filler; isotactic polypropylene; mixing

Acknowledgments

This work was supported by Japan Science and Technology Agency (JST), the National Natural Science Foundation of China (Grant Nos. 50803058 and 51273182) and Zhejiang Provincial Natural Science Foundation of China (No. Y4100221). The authors acknowledge Professor Qinguo Fan in University of Massachusetts and Dr. Jiping Wang in P&G Company for helpful discussions.

References

1 Wu H Y, Li X X, Xiang F M, Huang T, Shi Y Y, Wang Y. Microstructure evolution of isotactic polypropylene during annealing: effect of poly(ethylene oxide). Chinese Journal of Polymer Science, 2012, 30(2): 199–208

2 Jerabek M, Major Z, Renner K, Móczó J, Pukánszky B, Lang R W. Filler/matrix-debonding and micro-mechanisms of deformation in particulate filled polypropylene composites under tension. Polymer, 2010, 51(9): 2040–2048

3 Zhang Q X, Ya Z Z, Xie X L, Mai Y W. Crystallization and impact energy of polypropylene/CaCO₃ nanocomposites with nonionic modifier. Polymer, 2004, 45(17): 5985–5994

4 Thio Y S, Argon A S, Cohen R E, Weinberg M. Toughening of isotactic polypropylene with CaCO₃ particles. Polymer, 2002, 43(13): 3661–3674

5 Dou Q, Meng M R, Li L. Effect of pimelic acid treatment on the crystallization, morphology, and mechanical properties of isotactic polypropylene/mica composites. Polymer Composite, 2010, 31(9): 1572–1584

6 Radonjič G, Šmit I. Phase morphology and mechanical properties of iPP/SEP blends. Journal of Polymer Science Part B: Polymer Physics, 2001, 39(5): 566–580

7 Rotzinger B. Talc-filled PP: a new concept to maintain long term heat stability. Polymer Degradation & Stability, 2006, 91(12): 2884–2887

8 Yui H, Wu G Z, Sano H, Sumita M, Kino K. Morphology and electrical conductivity of injection-molded polypropylene/carbon black composites with addition of high-density polyethylene. Polymer, 2006, 47(10): 3599–3608

9 Kusmono, Mohd Ishak Z A, Chow W S, Takeichi T, Rochmadi. Effect of clay modification on the morphological, mechanical, and thermal properties of polyamide 6/polypropylene/montmorillonite nanocomposites. Polym Composite, 2010, 31(7): 1156–1167

10 Tang L X, Qu B J, Shen X F. Mechanical properties, morphological structure, and thermal behavior of dynamically photocrosslinked PP/EPDM blends. Journal of Applied Polymer Science, 2004, 92(5): 3371–3380

11 Švab I, Musil V, Pustak A, Šmit I.Wollastonite-reinforced polypropylene composites modified with novel metallocene EPR copolymers. I. Phase structure and morphology. Polymer composite, 2009, 30(7): 1007–1015

12 Wang B B, Wei L X, Hu G S. Synergetic toughness and morphology of poly(propylene)/nylon 11/maleated ethylene-propylene diene copolymer blends. Journal of Applied Polymer Science, 2008, 110(3): 1344–1350

13 Yang K, Yang Q, Li G X, Sun Y J, Feng D C. Mechanical properties and morphologies of polypropylene with different sizes of calcium carbonate particles. Polymer composite, 2006, 27(4): 443–450

14 Ruan W H, Huang X B, Wang X H, Rong M Z, Zhang M Q. Effect of drawing induced dispersion of nano-silica on performance improvement of poly(propylene)-based nanocomposites. Macromolecular Rapid Communications, 2006, 27(8): 581–585

15 Kuriyagawa M, Kawamura T, Hayashi S, Nitta K H. Reinforcement of polyurethane-based shape memory polymer by hindered phenol compounds and silica particles. Journal of Applied Polymer Science, 2010, 117(3): 1695–1702

16 Kuriyagawa M, Kawamura T, Hayashi S, Nitta K H. Effects of addition of hindered phenol compounds to a segmented polyurethane with shape memory on mechanical yielding. Journal of Materials Science, 2011, 46(5): 1264–1271

17 Thomas S, Groeninckx G. Reactive compatibilisation of heterogeneous ethylene propylene rubber (EPM)/nylon 6 blends by the addition of compatibiliser precursor EPM-g-MA. Polymer, 1999, 40(21): 5799–5819

18 Qi D M, Yang L, Wu M H, Lin H M, Nitta K H. Phenolic rigid organic filler/isotactic polypropylene composites. I. Preparation. Frontiers of Chemical Engineering in China, 2008, 2(3): 236–241

19 Suarez J C M, Coutinho F M B, Sydenstricker T H. SEM studies of tensile fracture surfaces of polypropylene-sawdust composites. Polymer Testing, 2003, 22(7): 819–824

20 Kim H S, Lee B H, Choi S W, Kim S, Kim H J. The effect of types of maleic anhydride-grafted polypropylene (MAPP) on the interfacial adhesion properties of bio-flour-filled polypropylene composites.Composites Part A: Applied Science and Manufacturing, 2007, 38(6): 1473–1482