A novel phenolic rigid organic filler (KT) was melt-mixed with an isotactic polypropylene (iPP) to prepare a series of PP/KT composites, with or without maleic anhydride grafted polypropylene (MAPP) as compatilizer. The evolution of filler morphology during melt-mixing and melt-pressure processes was monitored by scanning electron microscope (SEM) and polarized optical microscope (POM). The influences of shear force, pressure time, filler content and MAPP concentration on the final filler dispersion were studied. We found that this rigid organic filler readily melted and dispersed homogenously into the iPP matrix through a fission-fusion process during the melt-mixing process. Thus a balanced dispersion, which was closely related to shear force and MAPP concentration, can be achieved. During the meltpressure process, parts of the filler particles combined gradually through a coalescence process. However, the incorporation of MAPP can effectively inhibit the tendency to coalesce and refine the filler particles sizes into nanoscale. Thus, a series of PP/KT composites with controllable filler particles size and narrow size distribution can be obtained just by adjusting process conditions and MAPP concentration. In addition, due to the in-situ formation mechanism, the filler phase possessed a typical solid true-spherical shape.
A novel phenolic rigid organic filler (KT) was used to modify isotactic polypropylene (iPP). The influence of KT particles on the impact resistance property of PP/KT specimens (with similar interparticles distance, 1.8 μm) was studied by notched izod impact tests. It was found that the brittle-ductile transition (BDT) of the PP/KT microcomposites took place at the filler content of about 4%, and the impact strength attains the maximum at 5% (with filler particles size of 1.5 μm), which is about 2.5 times that of unfilled iPP specimens. The impact fracture morphology was investigated by scanning electron microscopy (SEM). For the PP/KT specimens and the highdensity polyethylene/KT (HDPE/KT) specimens in ductile fracture mode, many microfibers could be found on the whole impact fracture surface. It was the filler particles that induced the plastic deformation of interparticles ligament and hence improved the capability of iPP matrix on absorbing impact energy dramatically. The determinants on the BDT were further discussed on the basis of stress concentration and debonding resistance. It can be concluded that aside from the interparticle distance, the filler particles size also plays an important role in semicrystalline polymer toughening.
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