Single polymer composite sheets from polypropylene nonwoven fabric and films. Influence of processing conditions on final properties

Abstract Single polypropylene (PP) composites from a film/nonwoven fabric/film was obtained by hot calendering in order to develop recyclable, flexible, and low‐cost sheets. Processing temperature (T_p) influence on morphology and mechanical properties of developed single composites was analyzed. Two different values of roll temperature (140 and 150°C) were studied, keeping constant rotation speed and rolls distance. Results revealed notable differences in materials microstructure induced by a difference of only 10°C in T_p. Sheets obtained at 140°C presented a well‐defined film/nonwoven fabric/film structure, meanwhile the highest T_p led to a greater melting extent of external films which penetrate into the fabric, creating a more compact structure. Moreover, results confirmed that changes in T_p can induce a differential mechanical performance showing higher strength, and ductility in sheets processed at 150°C. Homogeneous sheets with good mechanical behavior, proper nonwoven fabric/films adhesion, and uniform thickness were obtained.