Plastic packaging materials of laminated composites made of polymer cover sheets and a nonwoven interlayer

This study aims to improve the mechanical properties, stabilized structures, and light weight plastic packaging materials to realize diverse applications. A sheet extrusion machine is used to fabricate sandwich-structured composites, which are composed of two polymer cover sheets and a nonwoven interlayer. The samples are prepared in two batches with different cover sheets: thermoplastic polyurethane and polypropylene. Moreover, low-melting-point polyester (LMPET) fibers and Kevlar fibers are fabricated into a LMPET/Kevlar nonwoven interlayer. The laminated composites are evaluated in terms of morphologies, mechanical properties, combustion rates, and thermal behavior. Kevlar fibers are flame resistant and mechanically strong. LMPET fibers promote the interfacial bonding between layers. Thus, the laminated composites are good candidates as packaging materials, and they can be made with rigid or soft materials, depending on specified requirements. Rigid materials can provide higher strengths, and the distribution of fibers thus helps the PP-based laminated composites to obtain higher crystal stability. Moreover, using TPU with flexibility contributes to high extensibility, which grants the laminated composites with high toughness, light weight, and low restriction against the morphology. Such manufacturing is also efficient and economical, thereby satisfying the requirements of plastic packaging materials.