In situ generation of high aspect ratio silica particles in polypropylene

Polypropylene/silica microcomposites with high aspect ratio silica fillers were in situ generated into a molten polypropylene (PP) matrix. The synthesis of the inorganic domains are based on hydrolysis-condensation reactions of both alkoxysilanes precursors, the tetraethoxysilane (TEOS) and the Dynasil® 40 (composed of TEOS and partially condensed TEOS with residual ethoxy groups) respectively. The sol–gel reactions kinetics studied at room temperature into an acid hydroalcoholic medium for several conditions of pH associated to the processing conditions were the keys factors to control the deformability of the inorganic droplets. Thanks to a shearing hot stage coupled with an optical microscope, silica needles were obtained with a Dynasil® 40 solution treated 120 min at pH = 3 in presence of 4 g of ethanol and then placed between two slices of PP in the stage. The deformation of the droplets were then observed once the material was molten and a shearing applied. On the contrary, no deformation was possible with TEOS precursors solutions. The results transposed to the microextruder process equipped at the die with a drawing line allowed to obtain a well pronounced elongated shape of the silica particles dispersed in the polypropylene matrix.