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Compounding of Polypropylene

There are three broad categories of alme retardant polypropylene

• Chlorine based systems
• Bromine based systems
• Non-Halogenated systems

There are a number of flame retardants available all over the world in each of the above system. The right choice
among them depends on the end application and the cost. Another important inorganic filler is antimony trioxide which
acts as a synergist with halogen i.e. mainly chlorine and bromine containing flame retardants. The halogen liberated
from these during burning reacts with antimony trioxide to form volatile antimony halides and oxyhalides. These enter
the gaseous part of the flame and help quench reaction occuring, thereby neutralizing free radicals. The antimony
trioxide also reacts directly with the polymer to give water which cools and dilutes the flame.

Manufacture of flame retardant polypropylene

In order to achieve uniform flame retardancy in the end product, compounding of polypropylene with all flame
retardant additives becomes extremely important. Some applications also require many other additives and fillers to be
incorporated in polypropylene along with flame retardants. This demands sophisticated compounding equipment and
quality control.

To manufacture high quality flame retardant polypropylene sophisticated machinery and technology are required.
Investment in machinery is very high even for medium sized manufacturing unit. These overheads, together with the
high rate of power consumption per unit weight of material manufactured, substantially add to the cost of the finished
product. However, this increase can be compensated by adding fillers, which increases the complexity of compounds.
Higher safety standards required by applications normally justify higher cost of flame retardant materials.

UL Classification
Following is the basics of Underwriters Laboratory specifications:

This is a flammability test devised by Underwriters Laboratories for plastic materials used in electrical devices and
appliances. In this test, specimens are exposed for two successive 10 seconds ignitions from 3/4" burner flame. They
are classified according to the time it takes the flame to extinguish and the length of time any"after glow" persists.

Rating are as follows:

94 V-O
Extinguishment time 0.5 seconds
After glow time 0.30 seconds
94 V-1
Extinguishment time 6-25 seconds
After glow time
No. flaming drips 0-60 seconds
94 V-2
Extinguishment time 0.25 seconds
After glow time
Flaming drips permitted 0-62 seconds

Chlorine based systems:

This is the most economic way to make Flame Retardant Polypropylene although recently highly advanced and
expensive systems are also available suitable not only for polypropylene but also for nylon, PBT etc.

Table 8 shows properties of flame retardant polypropylene made out of polypropylene homopolymer.

Table 8 : Flame retardant polypropylene- homopolymer chlorinated system

Property Units PP-FR
Density gm/cc 1.15-1.17
Mould shrinkage % 1.5-1.1.6
Mechanical properties kg/cm2 340

Tensile strength at yield

Tensile strength at break kg/cm2 270
Elongation % 20
Flexural strength kg.cm2 450
Izod Impact kg.cm/cm2 2.0

Notched 20.0
Unnotched kg.cm/cm2
Thermal Properties deg. C 60
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Heat Distortion temp. at 18.5
kgs.load
Flammability UL 94 V-0

Similarly Table 9 shows properties of flame retardant polypropylene copolymer. These are only typical examples of data
sheet properties. However, enough scope exists to further modify the properties as per the demands of applications. It
is also necessary to understand the limitations of this most economic system. The thermal stability and heat
resistance of flame retardant poly propylene is greatly reduced. Flame retardants also plasticise polypropylene is
mouldable at lower temperature. This reduces the heat distortion temperature and sets a limit to the applications
which need higher performance temperature. Chlorine based systems find application in small iinjection moulded parts
and is not recommended for any of the extrusion applications as it poses greater degree of damage to screw, barrel,
dies etc.
Table 9 : Flame retardant polypropylene- copolymer chlorinated system
Property Units PPC
Density gm/cc 1.15-1.17
Mould shrinkage % 1.5-1.6
Mechanical properties kg/cm2 300

Tensile strength at yield kg/cm2 250

Tensile strength at break

Elongation % 40
Flexural strength kg. cm2 400
Izod Impact kg.cm/cm2 5.0

Notched kg.cm/cm2 40.0

Unnotched
Thermal Properties deg. C. 55

Heat Distortion temp. at 18.5

kgs. load
Flammability UL 94

Bromine based system:

This is the best way of making propylene flame retardant. The end product has better thermal stability and hence
can be processed by injection moulding and extrusion. Heat deflection temperature is also not adversely affected.
Table 10 shows typical properties of polypropylene homopolymer based compounds.

Since this system is versatile and can be used in wider applications, it is extensively studies from the point of view
of smoke and toxicity hazards.

Polypropylene compounds having required properties can be tailor-made for give application by incorporating various
mineral fillers and glass fibres.

Table 10 : Flame retardant polypropylene- homopolymer brominated system

Property Units PPFRV-1

Unfilled PPH
Density gm/cc 1.24
Mould shrinkage % 1.8-2.0
Mechanical properties kg/cm2 330

Tensile strength at yield kg/cm2 275

Tensile strength at break

longation % 40
Flexural strength kg. cm2 460
Izod Impact kg.cm/cm2 3.0

Notched kg.cm/cm2 33.0

Unnotched
Thermal Properties deg. C. 96.0

Heat Distortion temp. at 18.5 kgs. load

Flammability 1mm UL 94 V-1
Table 11
Non-halogenated Flame retardant polypropylene-homopolymer

Non-halogen based systems

Smoke density and toxicity regulations limit the use of halogen based flame retardant polypropylene. Acidic halogen
based gases evolved during burning also damage expensive electronic circuitary. The development of non-halogenated

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systems took place considering these aspects. However, it is the most expensive system today for injection moulding
applications. It is widely used for extrusion applications mainly polyethylene based cables.

Table 11 gives properties of polypropylene homopolymer based product. Similarly compounds based on co-
polymer fillers and other additives can be made.
Property Units Unfilled PPH
Density gm/cc 1.04
Mould shrinkage % 1.8-2.0
Mechanical properties kg/cm2 315

Tensile strength at yield kg/cm2 270

Tensile strength at break

longation % 38
Flexural strength kg. cm2 430
Izod Impact kg.cm/cm2 2.3

Notched kg.cm/cm2 31.0

Unnotched
Thermal Properties deg. C. 87.0

Heat Distortion temp. at 18.5 kgs.

load
Flammability 1mm UL 94 V-0

• Elastomer Modified PP products

One of the most common reasons to utilize a rubber/elastomer "modifier" in PP is to improve its low temperature
impact resistance. Originally, the frist impact PP products were formulated from blends of PP homopolymer with butyl
rubber. Subsequently, it was discovered that ethylene-propylene (EPM) rubber offered greater toughening power and
was easier to disperse and compound into PP. The industry then evolved towards fine tuning of the EPM materials
with the closely related ethylene-propylene-diameter polymers (EPDM).

When EPM/EPDM rubbers are thoroughly blended with either PP homopolymer or copolymer to an extent of 10-40%
by weight, a new family of thermoplastic materials called rubber or toughened PP is produced. They have flexural
modulus of elasticity within 600-1200 MPa, together with an exceptional impact resistance down to - 50 deg. C
according to the grade and percentage of EPDM used. Such a combination has been the main reason for the
success of these materials in the automobile industry.

The three properties, elastic modulus in flexural mode, impact strength and brittle/tough transition temperature represent
the most important indicators for end-use behaviour of elastomer modified PP technical articles.

A single rubber particle acts as a centre of absorption and elastic redistribution in the surrounding area of the shock
wave caused in the material when a local impact is applied. The impact energy is, therefore distributed across a
large volume of material, decreasing local intensity when the finely dispersed elastomeric particles are numerous. Table
(12) lists some properties of EPDM modified PP vs EPDM content.
Table 12 Properties of Elastomer Modified Polypropylene:
Property Test Method Units Blend I Blend II Blend III Blend IV Blend V
Density D 1505 gm/cc 0.9-1.0 0.9-1.0 0.9-1.0 0.9-1.0 0.9-1.0
Tensile strength at yield D 638 kg/cm2 45 100 150 200 220
Elongation D 638 % 500 500 500 350 100

kg/cm2 1000
Flexural Modulus D790 % 7500 7500 10000 15000
Izod Impact D256 kg. cm/cm N.B N.B N.B 60 30

-Notched D256 kg.cm/cm N.B N.B N.B NB NB

-Unnotched
Shore Hardness D2240 Shore 85A 90A 70D 77D 85D
Applications O riungs, Automobile Bumpers Dashboards,
hoses, mats trims, toys, internal panesl
and mud flaps, refrigerator
bellows liners, window
profiles
Modification by Other Components
Elastomer modified PP grades require greater stiffness at elevated temperatures, better HDT and shape stability. Filler
can be added to improve these properties. Talc is generally used in 15 to 40% by weight of finished products.
EPDM-PP Talc compositions permit a wide range of possible proportions and corresponding broad performance area for
the commercial products.

I II III IV V

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PP: 50 60 70 80 90
EPDM: 50 40 30 20 10

Applications:
In the recent past, the most important uses of PP-EPDM blends has been in the automobile industry. Comparative
lightness, low cost and a wide range of mechanical properties are the main factors responsible for the continuous
growth of these materials since 1975. Their main use in car bumpers using either PP-EPDM flexible shapes mounted
on a rigid steel framework or fabricated self-supporting finished articles such as complete car front masks.

Suitable blends contain from 10 to 35% by weight
PP talc ternary blends find their biggest outlet as
cost cars. For this application stiffness and shape
splintering failures or dangerous sharp fragments
application.
of EPDM, according to flexibility and imapct requirements. EPDM-
interment panel dash boards in many models of low to medium
stability, coupled with an impact resistance high enough to avoid
in medium speed crashes provide these blends with an ideal

According to an estimate 90% of the OO-EPDM blends used are for the automotive industry atpresent. A summary of
filled and reinforced-PP products in the automobile industry is given in Table 13.

Table 13 Plastic Components in Maruti Esteem

Part Name Material Wt. in gms. No. of parts Wt. per car
(grams.)
Instrument Panel Filled PP 4000 1 4000
Glove box Filled PP 350 1 350
Glove box lid Filled PP 200 1 200
Garnish cowl ventilator Filled PP 210 2 420
Oil filer housing assembly Filled PP 650 1 650
Fan blade 80 W Filled PP 180 1 180
Fan Blade 120 W Filled PP 236 1 236
AC blower Filled PP 160 1 160
Air filter assembly Filled PP 800 1 800
Trim rear pillar Filled PP 150 2 300
Air ventilator assembly Filled PP 1275 1 1275
AC case and cover Filled PP 550 1 550
cooling
Boot component Filled PP 500 2 1000
Bumper (Front upper) PP modified 780 1 780
Bumper (Front lower) PP modified 2600 1 2600
Bumper (Rear upper) PP modified 730 1 730
Bumper (Rear lower) PP modified 3200 1 3200
• Compounding Machinery
Compounding of PP with additiives, fillers and reinforcements can be achieved using various types of machines
depending on cost and quality of mixing desired. A few of these are discussed in the section.

• Compounding low add levels

PP is generally an easily compounded material and the compounding of low-add-level products usually requires nothing
more than a dry solids mixer for preblending and a single-screw extruder for pelletizing. Extrusion temperatures will
depend primarily on the viscosity or melt flow rate of the PP homopolymer or copolymer component., with melt
temperatures typically falling between 190 deg. c. and 2245 deg. c. Depending on the equipment, PP may give lower
output rates on extruders than other polymers as a result of both its low density and its rheological properties.

At high melt flow rates, pelletizing may present some problems owing to the low melt strength. With specialized
equipment, melt flow rates as high as 1000 have been pelletized. Both hot-cut and cold-cut pellletizing systems are
suitable for PP. The choice usually depends on the equipment available as well as downstream processing
considerations. In some subsequent extrusion and injection moulding processes, the shape and size of the pellets will
influence the products processing behaviour. For example, the flat, thin wafer configuration characteristic of the hot cut
has been reported to cause slipping problem in the extrusion of thin film.

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