Development and characterization of an all‐olefin thermoplastic sandwich composite system

Abstract In this investigation an all‐olefin thermoplastic sandwich system was developed and characterized. Commingled glass fiber polypropylene (PP) composite was used as skin and HDPE (PE) foam with closed cells as core. Infra‐red heating was used for melting the surfaces of the substrates for surface fusion bonding with a cold press. Two tie layer films, viz. ethylene‐propylene copolymer (EPC) and HDPE/elastomer blend, were used as hot melt adhesives for bonding the substrates. Single lap shear joints were prepared from PP composite and PE foam adherends with a bonding area of 25.4 mm × 25.4 mm to determine the interface strength. EPC tie layer provided higher bond strength (27.4 kg/cm ² ) to the all‐olefin sandwich system than HDPE/elastomer blend based one (19.7 kg/cm ² ). For EPC tie layer based sandwiches, a mixed mode a failure was observed in the failed lap shear samples; about 40% is cohesive failure through tie layer, and the rest of failure was adhesive either at PP composite or PE surfaces. Environmental scanning electron micrographs (ESEM) reveal that in the process of surface fusion bonding, PE foam cells in the vicinity of 0.80 mm interphase area were coalesced with high temperature and pressure. No macro level penetration of tie layer melt front into foam cells was observed. As the surface morphology of foam was altered on account of IR surface heating and the PP composite bonding side had a resin‐rich layer, the bonding situation was closer to that between two polymer film surface.