6/19/2020 Techno - commercial information on plastics Industry - News on Plastics Industry - Plastemart.

com

Compounding of Polypropylene

Following the trends that have been established, mica is the next step up in the stiffness/HDT ladder. Likewise, it
results in further decreased impact. Mica is found in a platelet form rather than in the more particular form of
CaCO3. As the fillers pass from the particulate form through the platelet form on their way to a fibrous-type form,
the changes in physical properties correspond. From another viewpoint, as the aspect ratio, or length-to-diameter (or
thickness) ratio of the filler increases, strength tends to increase and impact to decrease. Mica offers outstanding
stiffness as well as increased HDT. These properties are further enhanced by the addition of a coupling agent. Table
(3a) summarizes data on some mica-filled PP.
Table 3 a : TYPICAL PRODUCT PROPERTIES OF MICA FILLED -PP
Property Unfilled 40% 40% Coupled 50% 50% Coupled
Melt flow rate, condition L,g/10 min. 4 2 2 1.5 2
Density, g/cc 0.903 1.23 1.23 1.36 1.36
Tensile strength (yield) MPa. 35 43 46 45 50
Flexural modulus(1% secant), MPa 1656 5796 6555 7245 8211
Rockwell R hardness 99 88 82 85 887
Heat deflection temperature (66 psi), deg.C 88 136 138 138 138
Heat deflection temperature (264 psi), 96 111 114 118 118
deg.C

Mica-PP composites can be as stiff as steel sheet, but weight only 45% as such. Mica filled PP products are
considered inexpensive substitute for glass fibre filled PP (Table 3b). An interesting use of mica is in PP-PE
coopolymer foam for loud speakers and musical instruments due to excellent acoustic properties of mica mineral. The
higher speed of sound in mica allows for a more compact speaker cone.
Table 3 b : Mechanical Properties of Mica & Glass - PP
Property Unfilled 20% 40%
Tensile strength, MPa 34 42 43
Flexural modulus, MPa 1311 6417 7176
Izod impact, J/m 24 42 35

Notched at 220 deg. C No Break 501 235

Unnotched at 22 deg. C
heat deflection temperature 58 125 108

deg. C at 264 psi

Mould shrinkage, % lengthwise 2.0 0.3 0.8

Glass -Fibre Reinforced PP

Glass fibre reinforced PP is a high growth segment of the market. These products have high tensile strength and
HDT. Applications include those areas requiring the chemical resistance of PP with the strength of engineering resins.
A drawback of these materials had been their tendency to distort in the final product. Recent advances have resulted
in easy-flow grades that significantly reduce this tendency to warp. Other developments include the production of
higher impact grades. These improvements have opened new applications in the appliance and industrial markets.

Typical fibre lengths of glass are1/8 to 3/16 inch, although longer fibres are available for specialty applications. The
standard glass diameter for PP applications is 13 microns. The factors influencing properties are the base resin, the
starting glass-fibre geometry, the compounding and processing techniques, the presence or absence and type of a
coupling agent. Table (4) lists typical properties of glass filled PP. Table (5) illustrates the effect of polymer type and
melt flow rate of physical properties using standard 3/16 inch starting fibre length and a coupling agent. As can be
seen the property balances available compare favourably with many other engineering materials.
Table 4 : Typical Product Properties of Glass filled-PP
Property Units Base - PP 20% glass 30% glass 40% glass filled PP
filled PP filled PP
Homo
polymer
Density g/cc 0.90 1.06-1.08 1.15-1.17 1.19-1.21
Tensile strength at yield MPa 35 35.5 36.0 37.0
Tensile strength at break MPa 23 32.5 35.0 36.0
Elongation at break % 60 30 20 30
Flexural strength MPa 330 440 450 450
HDT 66 psi deg.C. 75 90 97 112

Table 5 : Typical Product Properties of Glass Reinforced, Coupled Material

Property Homopolymer Copolymer

atozplastics.com/PrintFile.asp?REF=/webtech/upload/literature/compounding_page4.asp& 1/2
6/19/2020 Techno - commercial information on plastics Industry - News on Plastics Industry - Plastemart.com
20% 40% 20% 40% 20% 40%
Melt flow rate, condition L, g/10 min. 3 2 18 12 1.8 1.5
Density, g/cc 1.04 1.22 1.04 1.22 1.05 1.14
Tensile Strength (yield) MPa 83 103 77 99 61 86
Flexural modulus (1% secant), MPa 4209 6831 4071 7590 3450 4830
Heat Deflection temperature (66 psi ) 141 144 144 145 141 143
deg. C.
Heat deflection temperature 234 136 134 137 141 143
Notched Izod (23 deg. C) J/m 85 112 75 96 149 192

Applications of glass filled PP are in fan blades, head lamp housing, chemical process equipment, washing machine
tanks etc.

Table (6) demonstrates the effect of the type of coupling agent on PP. As can be seen, the coupling agent provides
a considerable increase in tensile strength. In addition, other properties, such as creep resistance are also improved.
The mechanism of the coupling agent is to form a bond between the sizing agent on the glass fibre and the
specially treated PP resin.
Table- 6 : Effect Coupling Agent on a 30% Glass-Reinforced PP
Property No. of Coupling Coupling Agent A Coupling Agent B
Agent
Melt flow rate, condition L, g/10 min. 15 12 12
tensile Strength (yield)MPa 71 88 100
Yield Elongation (%) 1.8 2.1 2..9
Flexural modulus(1% secant), MPa 6141 6279 6348
Heat deflection temperature (264 psi) 143 146 146
deg. C.
Notched Izod (23deg. C) J/m 69 85 96

Table (7) shows a comparison of properties of filled PP homopolymer

Property Units Base PP 20% 20% talc filled 20% glass 20% glass
Homopolymer CaCO3 filled reinforced
filled
MFI g/10 4 3 3.5 3.5 3.5
min.
Density g/cc 0.9 1.06-1.08 1.06-1.08 1.06-1.08 1.06-1.08
Mould Shrinkage % 2.1-2.3 1.6-1.8 1.5-1.7 0.8-1.0 0.8-1.0
Tensile strength at break MPa 23 18 25 32.5 80.0
Elongation at break % 60 70 50 30 -
Flexural strength MPa 33 35 47 44 61
deg.C 75 75 99 90 141

Other fillers and Reinforcements

Many other fillers and reinforcements also can be used with PP, including wood flour, ground corn stalks and other
cellulose containing substances. The cellulosic based products provide low-cost opportunities for achieving high stiffness,
but their applications is limited owing to their tendency to char and generate water at processing temperatures.

For the achievement of conductivity and/or static dissipation properties, metal powders, silver coated glass spheres,
metal wires and conductive carbons have been used. TO reduce the coefficient of friction and to improve wear
characteristics. TeflonR and Silicone are used. These systems are highly specialized and designed for particular
applications.

Colour Systems
The production of precoloured PP can be accomplished through the use of previously selected pigment systems that
have been distributed uniformly in the polymer. For successful colour matching, the viscosity of the resin, the ease of
pigment dispersion, the compounding equipment used and the selection of dispersing aids must be considered. In
order to ensure adequate dispersion, pigment systems are often predispersed in a masterbatch. When utilizing a
masterbatch, the carrier must be compatible with PP matrix.
In addition, the possible nucleating effect of certain pigments, heat stability of pigments which could affect processing
and physical properties of PP respectively must also be considered.

Flame Retardant PP
Materials used as flame retardants can be broadly classified as inorganic fillers and organic compounds. However, for
making polypropylene flame retardant most of the conventional inorganic fillers cannot be used. This is because of
high processing temperatures of polypropylene. At times, to achieve desired level of flame retardance substantial
quantities of inorganic fillers are required to be used. This affects the properties of end product drastically. Hence,
polypropylene is made flame retardant by using organic flame retardants.

atozplastics.com/PrintFile.asp?REF=/webtech/upload/literature/compounding_page4.asp& 2/2