Polypropylene Structure, blends and composites. Institute for Composite Materials Ltd, University of Kaiserslautern, Germany

Transcription

1 Polypropylene

2 Polypropylene Structure, blends and composites Volume 3 Composites Edited by 1. Karger-Kocsis Institute for Composite Materials Ltd, University of Kaiserslautern, Germany and Department of Plastics and Rubber, Faculty of Chemical Engineering, Technical University of Budapest, Hungary I unl SPRINGER-SCIENCE+BUSINESS MEDIA, B.V.

3 First edition Springer Science+Business Media Dordrecht Originally published by Chapman & Hall in 1995 Softcover reprint of the hardcover 1st edition 1995 Typeset in 10/12 Times by Interprint Limited, Malta. ISBN ISBN (ebook) DOl / Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the UK Copyright Designs and Patents Act, 1988, this publication may not be reproduced, stored, or transmitted, in any form or by any means, without the prior permission in writing of the publishers, or in the case of reprographic reproduction only in accordance with the terms of the licences issued by the Copyright Licensing Agency in the UK, or in accordance with the terms of licences issued by the appropriate Reproduction Rights Organization outside the UK. Enquiries concerning reproduction outside the terms stated here should be sent to the publishers at the London address printed on this page. The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made. A catalogue record for this book is available from the British Library Library of Congress Catalog Card Number: Printed on permanent acid-free text paper, manufactured in accordance with ANSI/NISO Z and ANSI/NISO Z (Permanence of Paper).

4 Contents List of contributors Preface List of contents for Volume 1 List of contents for Volume 2 VB ix xi xiii 1 Particulate-filled polypropylene: structure and properties 1 B. Pukanszky 2 Processing and properties of reinforced polypropylenes 71 A. G. Gibson 3 Fiber orientation prediction in injection molding 113 T. Matsuoka 4 Microstructural aspects of fracture in polypropylene and in 142 its filled, chopped fiber and fiber mat reinforced composites J. Karger-Kocsis 5 Glass mat reinforced polypropylene 202 L. A. Berglund and M. L. Ericson 6 Some wetting and adhesion phenomena in polypropylene 228 composites J. J. Elmendorp and G. E. Schoolenberg 7 Manufacturing methods for long fiber reinforced polypropylene 263 sheets and laminates D. M. Bigg 8 Thermoforming of unidirectional continuous fiber-reinforced 293 polypropylene laminates and their modeling R. Scherer 9 Fracture performance of continuous fiber reinforced 316 polypropylene B. Z. Jang

5 VI Contents 10 Interfacial crystallization of polypropylene in composites M. J. Folkes Index

6 Contributors Prof. L. A. Berglund Polymer Engineering Lule:1 University of Technology S Lule:1 Sweden Dr D. M. Bigg R. G. Barry Corporation PO Box 129 Columbus Ohio USA Dr J. J. Elmendorp Fasson/Roll Division PO Box NL Leiden The Netherlands Dr M. L. Ericson Polymer Engineering Lule:1 University of Technology S Lule:1 Sweden Prof. M. J. Folkes Department of Materials Technology BruneI University Uxbridge Middlesex UB8 3PH UK Prof. A. G. Gibson Department of Mechanical, Materials and Manufacturing Engineering University of Newcastle upon Tyne Newcastle upon Tyne NE17RU UK

7 viii Contributors Prof. B. Z. Jang Materials Engineering Department Auburn University Alabama USA Prof. J. Karger-Kocsis Institute for Composite Materials University of Kaiserslautern PO Box 3049 D Kaiserslautern Germany Dr T. Matsuoka Polymer Processing Group Toyota Central Research and Development Laboratories, Inc. Nagakute Aichi Japan Dr B. Pukanszky Department of Plastics and Rubber Technology Technical University of Budapest H-1111 Budapest Hungary Dr R. Scherer Hanseatische Aktiengesellschaft Elektrizitatswerk und Umwelttechnik SchloBmiihlendamm 1 D Hamburg Germany Dr G. E. Schoolenberg Koninklijke/Shell-Laboratorium PO Box 3003 (Badhuisweg 3) NL-1003 AA Amsterdam The Netherlands

8 Preface Crystalline polypropylene (PP) was invented in the early 1950s by independent groups in the United States and Europe. The commercial production of PP began in 1957 in the USA and in 1958 in Europe [1]. The reader will find different data about this issue in this book. On the other hand, there is no doubt that PP became the winner among the commodity of largevolume thermoplastics into the group of which polyethylene (PE), poly(vinyl-chloride) (PVC) and polystyrene (PS) belong, too. The mean consumption rate of PP was about 10% per year in the past, in given application fields this value was even higher. The forecast for the future trend of PP use is still quite optimistic. Which are the contributing factors to this success? The key factor is related with the versatility of PP per se. This means that the structure and properties (including processability) of PP can be tailored to requirements. Modifications of PP can be performed in different ways: during the polymerization (e.g. production of syndiotactic homo polymers or copolymers with different comonomer content), in the reactor (reactor-blends), in compounding (e.g. manufacturing of filled and chopped fibre reinforced grades) or in further separate processing steps (e.g. wetting of glass mat by PP-melt, manufacturing of textile composite preforms). PP exhibits many beneficial properties such as low density, relative high thermal stability, easy (re)processing and resistance to corrosion. In addition, its mechanical property profile is very closely matched to that of the engineering thermoplastics. The gap between the commodity PP and engineering thermoplastics can be filled when proper fillers and/or reinforcements are incorporated in the PP. This upgrading procedure, targeting enhanced stiffness, strength or even impact resistance and damage tolerance, represents the next milestone in the use and history of PP. Furthermore, it has been recognized only recently that the widespread application of thermoplastic matrix-based composites is hampered by high material and processing costs. Since PP offers in this respect economic benefits, a very extensive R&D activity has been started on PP-based composites. It can be predicted that this field will be the driving force for an increased PP consumption in the near future. It is for this reason that Volume 3 of this set is devoted to composites. Volume 3 gives a comprehensive overlook on

9 x Preface filled and reinforced systems with PP as a matrix material. The main emphasis is on the processing-structure-property (inter)relationships in filled and reinforced systems. The chapters cover all the aspects related to particulate filled, chopped fibre, fibre mat- and continuous fibre-reinforced PP composites. Since the above issues cannot be treated adequately without considering the interfacial phenomena (adhesion, wetting, interfacial crystallization etc.), these topics have also been included. My main aim with this volume was to demonstrate the microstructureproperty relationships on the example of PP-based composites by differentiating between general and peculiar features. I hope, therefore, that this volume will be a 'must' to all colleagues working on different fields of the processing and application of composites with various thermoplastic matrices. Comprehensive referencing included with each chapter, helps to reach this target. This book is designed to serve as guidelines for property improvement, upgrading and engineering use of PP and its different versions. It is for this reason that such important fields of PP application as textile fibres, packaging films and foils etc., are not covered. During editing I did not try to 'harmonize' the conclusions and opinions of the authors. The Romans used to say: Varietas delectat (variety is delightful) and I share this opinion, especially with respect to this volume, which informs the reader about research works from a rather early stage. Thanks are due to the contributors, who kindly agreed to cooperate on this 'venture', for their efficient work and - with one exception - for the timing of the manuscript delivery. I would like also to acknowledge the engaged work of the publisher Chapman & Hall, whose staff cut the time delay in the publication of this book, which was caused by the transfer of this title from Elsevier Applied Science. J6zsef Karger-Kocsis Kaiserslautern, Budapest A.m.D.g. Reference 1. H.R. Sailors and J.P. Hogan (1981) History of polyolefins, J. Macromol. Sci. Chern., A15,

10 Contents for Volume 1 Part One Polymorphism in Polypropylene Homo- and Copolymers 1 Molecular structure of polypropylene homo- and copolymers B. Monasse and J. M. Haudin 2 Crystallization structures of polypropylene homo- and copolymers S. Z. D. Cheng, J. J. Janimak and J. Rodriguez 3 Crystalline, melting and supermolecular structure of isotactic polypropylene J. Varga 4 Nucleation of polypropylene A. Galeski 5 Epitaxial growth on and with polypropylene J. Petermann Part Two Processing-induced Structure 6 Higher order structure of injection-molded polypropylene M. Fujiyama 7 Knit-line behaviour of polypropylene and polypropyleneblends G. Mennig 8 Welding and fracture of polypropylene interfaces R. P. Wool 9 Self-reinforcement of polypropylene J. Song, M. Prox, A. Weber and G. W Ehrenstein 10 Processing-induced structure formation H. Janeschitz-Kriegl, E. Fleischmann and W Geymayer

11 Contents for Volume 2 1 Manufacturing and properties of polypropylene copolymers P. Galli, J. C. Haylock and T Simonazzi 2 Primary spherulite nucleation in polypropylene-based blends and copolymers Z. Bartczak, E. Martuscelli and A. Galeski 3 Polypropylene alloys and blends with thermoplastics L. A. Utracki and M. M. Dumoulin 4 Structure and properties of polypropylene--elastomer blends E. M artuscelli 5 Orientational drawing of polypropylene and its blends S. V. Vlassov and V. N. Kuleznev 6 Thermoplastic elastomers by blending and dynamic vulcanization A. Y. Coran and R. P. Patel