Development of recyclable, lightweight polypropylene-based single polymer composites with amorphous poly-alpha-olefin matrices

In the present study, we produced and investigated polypropylene-based single-polymer composites (SPCs) using four amorphous poly-alpha-olefin (APAO) grades as matrices and two plain-woven polypropylene fabrics as reinforcement. Our goal was to investigate the applicability of APAOs as matrix materials of SPCs and to widen the processing temperature window of SPCs utilizing the low melting temperature of APAOs. We produced the composites with a double-belt press at 120 °C, 140 °C, and 160 °C, and investigated them by density measurement, and static tensile and dynamic falling weight impact (IFWI) tests at room temperature, −40 °C, and 80 °C. The composites showed adequate tensile and excellent dynamic mechanical properties. The tensile test results indicated that the optimal consolidation temperature is between 120 °C and 140 °C, depending on the matrix applied. Increasing the test temperature resulted in reduced tensile strength. Increasing processing temperature caused a drop in perforation energy because of the reduced extent of the delamination of the better-consolidated composites. Both static and dynamic mechanical properties can be improved with the use of a stronger fabric. Furthermore, the processing temperature window can be widened with APAOs as matrix materials, and these single-polymer composites possess many beneficial properties.