Structure–property relationship of melt spinning polypropylene fibers containing inorganic particulate CaCO₃ fillers

Abstract

Spinning technology using melt extrusion and spin-draw processes transforms polymeric materials into highly oriented, crystallized polymeric fibers. Thermoplastic isotactic polypropylene compound with ground CaCO3 (GCC) and precipitate CaCO3 (PCC) with stearic acid surface coating treatment was used in this study. This product was developed in masterbatch form, which contained 70% GCC in resin and 50% PCC in resin. The resulting (masterbatch pellets) polymer can be spun into fibers through a single-screw extruder. Surface and cross-sectional images of fibers were captured by optical microscopy and scanning electronic microscopy for identifying the organic/inorganic interface of fibers. The melt-spun fibers have a distinctive morphology, the particles impact on spinnability, and productivity in the spunbond will alter the mechanical property, thermal property and optical property of fiber-based products. Processing parameters, including spinning speed, throughput rate and take-up roll velocity, were systematically study to understand the structure formation. Meanwhile, different loading concentrations are applied for varied factor comparison of particle size and shape. The Weibull distribution model is applied for determining the tensile property of fibers containing high GCC dosages of 20–40%. Meanwhile, a few more steps of gauge length are utilized for studying the probability of a weak link in polymer materials. Through a systematic discussion of the GCC and PCC comparison study in changing fiber properties, the impact of the particle size on agglomeration formation is emphasized, as well as the breaking mechanism of fibers.

Light‐weight and high‐strength PP/CaCO3 composites by die drawing: Effect of drawing ratios

“…Wei et al's studies showed that the tensile strength of highly oriented polypropylene/multiwalled carbon nanotube (PP/MWCNT) composites prepared by die drawing was increased by 550%. [21] Die drawing can also reduce the material's density by forming voids. Rane et al [18] studied die drawn Talc-filled PP and die drawn unfilled PP with different drawing ratio.…”

“…Wei et al's studies showed that the tensile strength of highly oriented polypropylene/multi‐walled carbon nanotube (PP/MWCNT) composites prepared by die drawing was increased by 550%. [ 21 ]…”

Synthesizing heat transfer factors on thermal bonding structure of mineral added polypropylene spun‐bond

“…When there are two phases, interstice around particles later bear high tension along fiber deformation would form as strength weak link along such as fibers in its stress–strain deformation. Furthermore, a two‐phase system in thermal calendar bonding inspect any cracks at weak interphase of filler‐polymer mixing phase 18 ; fiber strength depends on loading configuration in fibers 19 . Within the structure, particles may weaken fabric structure aspects as a form of the cavity, but the tenacity level will depend on structural factors.…”

“…The input parameters for single fibers tensile were recorded as the linear density of denier (gram/9000 m) in 1.5 denier to 10 denier. The previous articles have mainly documented the testing procedures 19 …”

“…Furthermore, a two-phase system in thermal calendar bonding inspect any cracks at weak interphase of filler-polymer mixing phase 18 ; fiber strength depends on loading configuration in fibers. 19 Within the structure, particles may weaken fabric structure aspects as a form of the cavity, but the tenacity level will depend on structural factors. This deterioration could reach up to 20 wt.%.…”