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<p>Highly filled polypropylene composites incorporating low-cost inorganic fillers, calcium carbonate and talc, were prepared by extrusion and injection molding. The balance between processability, density, melt flow, impact, tensile, and flexural properties was evaluated across multiple polypropylene-based formulations, containing either calcium carbonate or talc, with and without selected additives. The incorporation of small amounts of functional additives significantly enhanced processability by increasing the melt flow index and improving impact resistance, while maintaining the high stiffness characteristic of filled PP composites. Industrial-scale injection molding trials using these highly filled formulations confirmed their suitability for complex-shaped products. Furthermore, the mechanical recycling of these formulations was simulated through successive re-extrusion cycles. Despite the elevated level of melt flow index, the formulations demonstrated considerable stability in their key mechanical properties throughout the reprocessing cycles.</p>

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Enhancing processability and mechanical properties of highly filled polypropylene composites through adapted co-additives

  • 期刊论文

  • 发表日期：

    2026年7月16日

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  • Aziz Fihri,
  • Jevgenij Lazko,
  • Jérôme Mariage,
  • Loïc Brison,
  • Fouad Laoutid,
  • Haleema Alamri,
  • Yassine Malajati,
  • Kholod Alamoudi,
  • Nada Qari,
  • Ruchi Rastogi,
  • Philippe Dubois

摘要

Highly filled polypropylene composites incorporating low-cost inorganic fillers, calcium carbonate and talc, were prepared by extrusion and injection molding. The balance between processability, density, melt flow, impact, tensile, and flexural properties was evaluated across multiple polypropylene-based formulations, containing either calcium carbonate or talc, with and without selected additives. The incorporation of small amounts of functional additives significantly enhanced processability by increasing the melt flow index and improving impact resistance, while maintaining the high stiffness characteristic of filled PP composites. Industrial-scale injection molding trials using these highly filled formulations confirmed their suitability for complex-shaped products. Furthermore, the mechanical recycling of these formulations was simulated through successive re-extrusion cycles. Despite the elevated level of melt flow index, the formulations demonstrated considerable stability in their key mechanical properties throughout the reprocessing cycles.